Flume Final Report 2012

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TRANSMITTAL

Florida Institute of Technology

Department of Marine and Environmental Systems

OCE 4541

TO: Dr. Stephen WoodDepartment of Marine and Environmental Systems

Florida Institute of Technology150 West University Blvd.

Melbourne, FL 32901

FROM: Team N.A.R.W.H.A.L.E.s

150 West University Blvd.

Melbourne, FL 32901

RE: Final Design Report

Dr. Wood,

The following report for N.A.R.W.H.A.L.E.s senior design project is being submitted foryour review. We have included all sections stated under the report contents. Thank you and

please contact us at [email protected] if you have any further questions.

Jacob Strom Mallory Bond Harrison Gardner

Jeffrey Bell Erica vonBampus


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NARWHALEs

Final Design Report

Summer 2012

ybeetirW:

Erica [email protected]

(407) 324-6321

Mallory [email protected]

(850) 319-6375

Jacob Strom

[email protected]

(716) 807-2223

Harrison Gardner

[email protected]

(630) 880-1130

Jeffrey Bell

[email protected](732) 513-9236
mailto:[email protected]:[email protected]:[email protected]:[email protected]:[email protected]:[email protected]:[email protected]:[email protected]:[email protected]:[email protected]:[email protected]:[email protected]:[email protected]:[email protected]:[email protected]


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Table of Contents

1.0Introduction ................................................................................................................................ 7

1.1 Motivations ........................................................................................................................... 7

1.2 Objectives ............................................................................................................................. 8

1.3 Organization .......................................................................................................................... 8

2.0 Background ............................................................................................................................... 9

2.1 Basic Theory ......................................................................................................................... 9

2.2 Historical Theory ................................................................................................................ 12

3.0 Procedures ............................................................................................................................... 27

3.1 Customer Requirements ...................................................................................................... 27

3.2 Engineering Specifications ................................................................................................. 27

3.3 Function Decomposition Structure ..................................................................................... 46

4.0 Results ..................................................................................................................................... 49

5.0 Conclusion .............................................................................................................................. 52

6.0 Recommendations ................................................................................................................... 52

Appendixes ................................................................................................................................... 53

A -- References ......................................................................................................................... 53

B -- Resources ........................................................................................................................... 53

C -- Safety Plan ......................................................................................................................... 54

List of FiguresFigure 1: Boundary Layer Diagram [10] ...................................................................................................................... 11

Figure 2: Patent No. 1,061,206 [9] ................................................................................................................................. 13

Figure 3: Diagram of Tesla Pump [8]............................................................................................................................. 14

Figure 4: Photograph of Insides of Tesla Pump [8] ................................................................................................. 14

Figure 5: Photograph of a Tesla Pump [8]................................................................................................................... 14

Figure 6: Diagram of a DiscFlo Pump [4] ..................................................................................................................... 15

Figure 7: Photograph of DiscFlo pump in use [4]..................................................................................................... 16

Figure 8: Diagram of University of Otagos Flume [6] ............................................................................................ 17

Figure 9: Photograph of University of Otagos Flume [6] ..................................................................................... 17

Figure 10: Aquabiotechs Flume [1]............................................................................................................................... 19

Figure 11: Maelstrom ........................................................................................................................................................... 20

Figure 12: Maelstrom Motor ............................................................................................................................................. 21

Figure 13: Maelstrom Chiller ............................................................................................................................................ 21

Figure 14: eFlows Bilge Pump Design [10] ................................................................................................................ 22

Figure 15: eFlows Paddlewheel Design [10] ............................................................................................................. 23

Figure 16: eFlows Paddlewheel [10]............................................................................................................................ 23

Figure 17: eFlows Tesla Pump [10] .............................................................................................................................. 24

Figure 18: eFlows Final Design [10] ............................................................................................................................. 25

Figure 19: eFlows Fluent Analysis [10] ....................................................................................................................... 25


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Figure 20: Fabricated Tank ............................................................................................................................................... 26

Figure 21: Fabricated Center Divider ............................................................................................................................ 26

Figure 22: Computer Model of Tank .............................................................................................................................. 28

Figure 23: Tank as Fabricated .......................................................................................................................................... 28

Figure 24: Window Jig ......................................................................................................................................................... 29

Figure 25: Cleaning the Glass ........................................................................................................................................... 29

Figure 26: Placing Top Pane on Foam Tape ............................................................................................................... 30

Figure 27: Pouring Resin into Window ........................................................................................................................ 30Figure 28: Refined Window Making Method ............................................................................................................. 31

Figure 29: Cardboard Funnel............................................................................................................................................ 31

Figure 30: Computer Drawing of Center Divider ..................................................................................................... 32

Figure 31: Computer Model of Center Divider in Tank ......................................................................................... 33

Figure 32: Computer Model of Tesla Pump ................................................................................................................ 33

Figure 33: Preform Mold .................................................................................................................................................... 34

Figure 34: Mold Lined with Fiberglass ......................................................................................................................... 34

Figure 35: Lining of Mold with Fiberglass ................................................................................................................... 35

Figure 36: Injection of Foam into Mold ........................................................................................................................ 35

Figure 37: Closing of the Mold ......................................................................................................................................... 36

Figure 38: Allowing Foam to Cure .................................................................................................................................. 36

Figure 39: Finished Preform in Mold ............................................................................................................................ 36Figure 40: Wooden Mount for Telsa Disks .................................................................................................................. 37

Figure 41: Tightening the Ratchet Strap ...................................................................................................................... 37

Figure 42: Sanding Joints.................................................................................................................................................... 38

Figure 43: Smoothing the surface of the disk ............................................................................................................ 38

Figure 44: Disk after being Spray Painted ................................................................................................................... 39

Figure 45: Gluing the Flange to the Disk ...................................................................................................................... 39

Figure 46: Spraying Gel Coat on the Disk .................................................................................................................... 40

Figure 47: Layering fiberglass cloth on the disk ....................................................................................................... 40

Figure 48: Finished Mold on Disk ................................................................................................................................... 41

Figure 49: Removing Excess Fiberglass ....................................................................................................................... 41

Figure 50: Buffing the Disk ................................................................................................................................................ 42

Figure 51: Flange to Connect Disk to Shaft ................................................................................................................. 43

Figure 52: Motor and its Controller ............................................................................................................................... 43

Figure 53: Example of a Chain Drive System ............................................................................................................. 44

Figure 54: Motor Mount ...................................................................................................................................................... 44

Figure 56: Construction of Motor Housing Sides ..................................................................................................... 45

Figure 57: Motor Housing Under Construction ........................................................................................................ 45

Figure 58: Final Assembly .................................................................................................................................................. 45

Figure 59: Final Location .................................................................................................................................................... 46

Figure 60: Final Drawing of Tank ................................................................................................................................... 47

Figure 61: Final Drawing of Center Divider ................................................................................................................ 48

Figure 62: Drawing of one Disk ....................................................................................................................................... 48

List of AbbreviationsNARWALE.Naval Architecture Recirculating Water Hydrodynamic Apparatus for LaminarExperimentation

AUV....Autonomous Underwater VehicleROV.Remote Operated VehicleDMES..Department of Marine and Environmental Systems


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List of Equations

Reynolds Number [2.1.1]

Reynolds Number for a Rotating Disk

[2.1.2]

Displacement Thickness

[2.1.3]

Momentum Thickness

[2.1.4]

Boundary Layer for Rotating Disk

[2.1.5]

Hydrodynamic Drag

[2.1.6]

Drag Coefficient for Rotating Surface [2.1.7]


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Executive Summary

Model testing is a very important aspect in many fields of study; however, it can become

very expensive when large facilities and testing apparatuses are required. The goal of this project

is to design and build a transportable testing tank for projects such as AUVs, the growth of oyster

beds, model ships, ROVs, and other ocean engineering projects designed to operate in a current.

To meet these requirements the NARWHALE team is designing a flume that will circulate a

laminar flow of water with a Tesla pump.

The Tesla pump will create an even laminar flow over the length of the tank and will be

operated by an electric motor attached to the tank. The Tesla drive will pull water to one side of

the flume and propel it underneath a water column divider where it will then emerge at the

opposite end of the tank. This will create an endless cycle of flowing water that will be able to

achieve a laminar flow. This system will replace large tow tanks and allow for more efficient

hydrodynamic testing. The Tesla pump will consist of six disks which rotate vertically dragging

water around the center divider. The tank has aluminum sides with windows that will allow the

testing to be monitored. Upon completion, the flume will benefit research and academics on

campus.


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1.0Introduction1.1 Motivations

Designing and constructing a flume would have several advantages to the university and

its students. Making the flume 10 times the size of the wave tank will allow a wider range ofocean engineering projects to be tested. The flume will enable optimal research and education for

students at the university and other educational facilities. In addition to this other companies and

organizations can use the flume to conduct studies bringing in an income for Florida Tech.

The flume will improve all hydrodynamic research done on campus greatly. Model

testing on campus is currently done in the wave tank, which is 30 inches wide by 30 feet long.

Larger ocean engineering projects cannot be tested in the wave tank due to size constraints.

Testing is also very difficult for any projects that need to be submerged due to the wave tanks

depth and towing method. The flume will provide a way to accurately test models and some full-

scale projects at precise flow rates and velocities as well as varying depths. The flume will be

useful to other departments as well. It could be used to conduct studies on marine organisms

where a current is needed. It could also be used to very accurately conduct long-term

experiments without needing to be deployed in the field.

The flume will be a great tool for education on campus improving many classes and labs

in areas such as fluid mechanics, naval architecture and marine biology. The scope and accuracy

of fluid mechanics classes and labs could be greatly improved by the flumes ability to create a

large volume of closely controlled laminar flow. The flume could benefit marine biology

research on campus with its ability to circulate water in a manner that will not harm any marine

organisms in the water. Theoretical concepts taught in class such as forces on an object, drag and

the stability of a floating object could be better demonstrated giving students a practical

understanding and experience.

The flume will also benefit the community. Parties outside of campus would be able to

conduct studies in the flume bringing in an income to Florida Tech. For instance, high school

students would be able to conduct studies in the flume, greatly benefiting their education and the

reputation of the university. Local companies and organizations could have research done in the

flume, giving the Florida Tech students experience and providing the university with grants and

corporate contacts.


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1.2 Objectives

The main objective of the NARWHALE group is to demonstrate a thorough

understanding of, and the ability to, apply fundamental engineering concepts. This will beaccomplished by designing and building a flume that meets all of its design requirements and

specifications, and that is capable of withstanding all of the stresses and forces applied to it

during its operation without failing. The project will also be done in the most economical and

efficient way possible.

The flume must be able to produce reliable and accurate data during experimentation. To

accomplish this, the flume will be designed to produce the smoothest and most laminar flow

possible. Water flow will be as constant as possible both throughout the length of the testing area

and the depth of the flume, enabling accurate testing for a wide variety of objects.

The flume will be designed so that the velocity of the water in the flume can be closely

controlled, changed and monitored. The Tesla pump and motor system will be designed so that it

is capable of creating a precisely controlled and easily adjustable flow in the tank.

The flume must also be portable. The flume will be able to be taken apart if needed so

that it can be moved to a new location. If experimentation needed to be conducted off campus or

if the university were to decide that the flume needed to be moved, then the flume would have to

be moved quickly, without excessive equipment such as a crane, and without being damaged.

1.3 Organization

Organization is important in moving this project through the design process. It is

necessary to move the project from a conceptual design, to a product design, to production, and

then service in a professional manner, and on schedule.

The organization of the project will be maintained mainly by the use of a designnotebook. The design notebook will keep all of the project files in one location. Copies of all

designs will be kept, whether the designs are conceptual drawings done by hand on engineering

paper or formal CAD drawings used to fabricate parts. The design notebook also contains all of

the calculations performed so that they can be checked; double checked, and reviewed, ensuring

that the flume is structurally sound and safe to operate. It will also contain all records of


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donations, purchases and expenses, so that the groups budget can be constantly monitored and

utilized.

Making sure that every deadline and due date is met will be very important. This will be

accomplished primarily through the use of a Gantt Chart. The Gantt Chart will clearly state when

each part of the project is intended to be worked on and completed by. This will make it easy forthe group to stay on task and avoid falling behind schedule. Weekly updates have been and will

be sent to Dr. Wood so that the progress of the project can be monitored and critiqued.

A daily journal is also being kept which records the number of hours worked by each

group member and the tasks accomplished. This will be used to keep track of exactly how many

hours went into the project and when tasks were accomplished. This will also be used to keep

track of whom the group consults with and how long the consultations lasted.

2.0 Background

2.1 Basic TheoryThe Reynolds Number is a dimension number that represents the ratio of inertial forces

to viscous forces in a liquid [2] The Reynolds number is fundamental to fluid mechanics, used in

many calculations, and will be important to the flume for several reasons. It is used in the

calculations for the boundary layer thickness and coefficient of friction which will need to be

calculated to optimize the design of the Tesla pump. The Reynolds number is also vital to model

testing. Reynolds number similitude is used to accurately test scale models and will have to be

used to find the maximum free stream velocity that the flume must be designed to be able to

generate. The Reynolds number can be calculated over a surface using the equation:

[2.1.1]

Where V is the free stream velocity, L is a representative length, and is the kinematic

viscosity of the fluid [2]. The Reynolds Number of a rotating disk can be calculated more

accurately through the equation:

[2.1.2]

Where r is the disks radius, is the angular frequency, is the swirl factor, and is the

kinematic viscosity [7].


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The boundary layer thickness is the distance off of a surface into a moving fluid to which

the effect of the surface is still felt. A boundary layer develops over surfaces along which an

inviscid fluid is traveling. At the edge of the surface a no slip condition develops where the

velocity of the fluid is zero. The velocity of the fluid then increases exponentially as it moves

further away from the surface [2]. There are three main ways to calculate the boundary layerthickness. The first way is the arbitrary method which uses the arbitrary value as seen in figure

1.The boundary layer is determined to contain the fluid moving at less than 99% of the free

stream velocity.

The second method is the displacement thickness method. This method calculates the

volume of fluid that affected by the nonslip condition at the surface boundary.

[2.1.3]

The third method is the Momentum thickness method. This method works by calculating

the momentum of the water that has been affected by the surface it is traveling over, and the

liquids effect on the surface.

[2.1.4]


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Figure 1: Boundary Layer Diagram [10]

The boundary layer over the disks will need to be calculated to determine the most

efficient spacing of the disks and will also need to be calculated along the length of the tank to

avoid boundary layer separation and added turbulence associated with it at high testing speeds.

In this project the boundary layer over the Tesla Pump disks was calculated with the equation for

a rotating disk:

[2.1.5]

In this equation D is the diameter of the disk, and Re is the Rotational Reynolds Number.

Hydrodynamic drag over a surface is the resistance to motion through a fluid felt by the

surface; this is calculated using the following equation:

[2.1.6]

In this equation, Cdis the coefficient of drag, is the density of the fluid, V is the free streamvelocity, and A is the characteristic area of the surface [7]. The drag coefficient for a rotating

surface can be found with the equation:

[2.1.7]

where Re isthe Rotational Reynolds Number[7]. The drag over each side of the disks must be


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found in order to calculate the torque needed to be generated by the motor which will spin the

Tesla pump. This torque is also needed to calculate the cross section of the central shaft needed.

2.2 Historical Theory

The Tesla pump, U.S. Patent 1,061,206 -- May 6, 1913 was invented by Nikola Tesla as ameans to extract energy from water. The design uses waters salient properties of adhesion and

viscosity [9] to create mechanical motion from a moving fluid. The Tesla pump consists of a

chamber, which houses a number of round flat disks spaced very close together. These disks are

keyed to a shaft, which is then geared to an electrical generator. The dimensions, number, and

spacing of the disks is to be determined by the application of the pump. The pump is meant to be

placed in a quickly moving fluid. The fluid is directed into a valve at the top of the pump and

into the pump chamber where it will circulate several times before being discharged through the

valve at the bottom of the pump. As the water circulates in the chamber, its viscosity surface

friction causes the pump disks, shaft and electrical generator to spin with it [9]. Figure 2 shows

the original application for a patent, filed October 21, 1909, and the Tesla Pump design.


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Figure 2: Patent No. 1,061,206 [9]

Tesla also patented a system that used this technology that he believed to propel water in

a more efficient manner than the pumps used at the time. This apparatus is US Patent # 1,061,14

"Fluid Propulsion." This pump caused the water being pumped through it to move in natural

paths or streamlines of least resistance [8]. Like the Tesla turbine it used spinning flat disks.

Tesla wrote that skin friction on the disks would cause the water to circulate in the chamber. The

fluid was sucked into the chamber at the center of the disks. An outflow was positioned at the top

of the chamber and pointed in direction of the flow. He determined that this was the optimal

shape and configuration for the pump, his designs can be seen in Figure 3. Figures 4 and 5 showa working prototype of this design, the casing has been removed in Figure 4 to show the disk

system.


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Figure 3: Diagram of Tesla Pump [8]

Figure 4: Photograph of Insides of Tesla Pump[8]

Figure 5: Photograph of a Tesla Pump[8]

DiscFlo Corporation located in California designs and manufactures pumps which use

Tesla pump. The company founder Max Gurth experimented with the Tesla pump design in 1970

to make it more efficient and useful as a pump. He found that widening the blades from Teslas

design allowed more fluid into the pump and increased efficiency. These pumps are used in an


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extremely wide range of applications with great success. DiscFlos patented pumps have

exceeded in many situations where other more commonly used pumps have failed. The pumps

have had great success in situations where the fluid being pumped needs to be laminar, the fluid

is abrasive, contains live organisms, is highly viscous, is air entrained, or has suspended solids in

it[4]. These applications are commonly found in the oil and petrochemical, municipalwater/wastewater, food and beverage, and steel manufacturing industries. Figure 6 shows the

basic design of a majority of these pumps. The pumps consist of a Tesla Turbine with more

widely spaced disks, which has been integrated into the housing of the motor. Depending on the

application of the pump and the torque requirements, the motor is either electric or gas powered.

The Tesla pumps pull fluid into the pump from a pipe mounted to the chamber perpendicular to

the disks. The disks then have holes in their centers to allow the fluid to travel through the

chamber. The flow leaves the chamber through a pipe fitted tangentially to the disks. This

arrangement provides a laminar flow.

Figure 6: Diagram of a DiscFlo Pump [4]

Pharmaceutical Co/ESI Technologies in Ireland needed to pump a crystal slurry in their

pharmaceutical manufacturing process. The crystals suspended in the slurry were extremely

susceptible to shear stress and needed to be pumped in a very smooth laminar fashion. The plant

originally used a progressive cavity pump and a centrifuge that caused severe pressure changes

and damages to the crystals in the fluid. DiscFlos pumps were able to produce a laminar flow

that did not destroy the crystals during pumping. To further eliminate shear stress caused by the

Tesla Turbine the disks were fabricated out of highly polished and smoothed stainless steel, and

the motor chosen was able to precisely control and adjust the speed of the disks[4].


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Harbor Branch in Florida uses DiscFlo pump to pump sea water without damaging the

live organisms in it. The pump is being used specifically by the Bio-Fence system from Applied

Photosynthetics to pump water containing algae. Some of the species of algae would be damaged

by a standard impellor or cavity pump. The Tesla pump however is able to pump the live

organisms without damaging them [4].In this particular situation the disks in the pump weremade from delrin to avoid corrosion over long periods of time in the pump.

Allegheny Ludlum is a steelmaker in Pennsylvania. The company uses DiscFlo pumps

because of their ability to pump extremely abrasive fluids. The plant initially used end suction

pumps to pump the fluid. These pumps however failed an average of 4 times a year. The plant

installed DiscFlo pumps and immediately solved their problems. The fluid being pumped in the

plant is hydrofluoric/nitric acid at 1800F. The fluid also contains ceramic brick particles a half

inch in diameter [4]. The simple design of the Tesla Pump allowed the disks being used to be

manufactured out of a ceramic material which could withstand the corrosiveness of the acids.

The spacing between the disks also allows particles to travel freely through the disks and

chambers without being caught or causing any damage.

Figure 7: Photograph of DiscFlo pump in use [4]

The University of Otago in New Zealand designed and built a flume on the Otago

campus. The flume was primarily designed for the schools athletic program. It was designed to

circulate water at the pace of a swimmer, giving it a range of .6 to 10 knots, covering novice to

Olympic swimmers. The flume has also been used by canoe and kayak paddlers for workouts.

The overall dimensions of the flume are 21 meters long, 4 meters deep and 4 meters wide; it was

designed to be large enough to perform hydrodynamic testing on the schools surf skis, paddle


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boards and rowing shells [6]. The flow is pulled through the flume by large axial flow pumps and

then pumped to the other end through pipes under the flume. The flume uses guide vanes to

direct and straighten out the flow. To keep the flow laminar the pipes empty into large reservoirs

at the ends of the flume [6]. The flume then gets narrower in the testing section to increase the

velocity.

Figure 8: Diagram of University of Otagos Flume [6]

Figure 9: Photograph of University of Otagos Flume [6]


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Aquabiotech Inc. located in Coaticook, Canada has developed an artificial river system.

This artificial river re-circulates water through a 12 foot testing section. This system was

designed for conducting experiments on marine organisms that would be found in a river

ecosystem. The testing chamber is meant to be filled with specimens and substrates that wouldbe found in a natural environment such as sand and burrowing organisms. The artificial river is a

487 centimeter long rectangular box made of acrylic. The box is 50 centimeters deep and 50

centimeters wide. The testing velocities range from 5 to 50 centimeters per second and is

powered by a 1 horse power pump. The water is pumped through a 12 inch diameter pipe under

the tank and is pumped through a honeycomb block with inch in diameter cells to even out the

flow and prevent fish from swimming into the pump [1]. The tank is also designed to be attached

to a chiller to closely control the temperature of the river and to counteract the addition of heat

from friction and the pump.


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Figure 10: Aquabiotechs Flume [1]

A Florida Tech senior design project led by Brian Biera was started to find a way to

conduct long term experimentation in moving water. The group determined that circulating water

in a circular tank would be the best way to accomplish this. The original design consisted of a

circular tank with a paddlewheel in the center of the tank which spun horizontally, moving water

around the edges of the tank [3]. This design was found through testing to create unsteady flow.

The design was then changed to use a Tesla Pump in place of the paddlewheel. The Tesla Pump

was suspended in the tank by bearings on the lid and bottom of the tank. The tesla pump disks

were 6 feet in diameter, constructed of coated plywood. The thickness of the boundary layer was


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calculated to be 74 mm. From this information the optimal spacing of the disks was determined

to 148mm[3]. Through testing the Tesla Pump was found to create a very laminar and constant

flow over long periods of time. The plywood disks eventually failed under the pressure changes

due to the changing velocities of the water in the tank and were replaced with disks constructed

of a honeycomb core fiberglass composite, holes were also added to the disks which were 63.5mm in diameter and are as close to center as possible in order to equalize pressure [3]. Figure11

shows this tank in its current location outside of Fruehauf, building 427.

Figure 11: Maelstrom

This design uses a 7.5 horsepower motor seen in Figure 12. This motor has successfully

powered this Tesla Pump at speeds of 10 knots without any complications or failures for the past

3 years. A three phase motor with a detachable controller was used so that the revolutions per

minute of the pump could be closely controlled. The three phase motor adjusts its voltage to

maintain the RPM set by the controller. The controller also allows a routine to be programmed

into the motor to allow the water to be gradually brought up to speed.


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Figure 12: Maelstrom Motor

It was also found that the friction in the water caused a good amount of heat buildup so a chiller

was added to the system to counteract this as seen in figure 13.

Figure 13: Maelstrom Chiller

The NARWHALE group is continuing eFlows senior design project. eFlow made

considerable progress in designing and building the flume. This years team will add to, improve,

and expand on eFlows designs. The eFlow team prepared a report, analyzed the flow in their


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design using computer software, and began construction on the tank, the exterior structure which

will hold all of the water.

eFlow prepared and submitted a report detailing their designs and plans for the flume.

This report explained the progression of designs that the group went through in coming up with a

final plan. The group originally thought to propel the water through the test section with a seriesof bilge pumps.

Figure 14: eFlows Bilge Pump Design [10]

This figure shows how the bilge pumps would be positioned at the end of the testing

section to pull water through the flume, where it would then be returned to the other end of the

tank through a pipe under the flume. The bilge pumps had the advantage of being water proof

and easy to maintain. The pumps however would create a turbulent flow and the pipe under the

tank would create eddies as water was re-circulated. This flume was also meant to be deployed

into a body of water such as a pool. It was designed to be small enough to be easily put into and

taken out of a pool, so that the tank didnt need to be filled and drained after each experiment.

This design also avoided the problem of water draining limits. In the state of Florida it is illegal

to dump more than 2000 gallons of freshwater a day, which would be easy to exceed with a large

tank. The small reservoir however would not give the water a long enough period of time tostraighten and smooth out. These draw backs led to the next design which used a larger tank, a

paddlewheel to propel the water and a water column divider to separate the two directions of

flow as seen in figure 15.


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Figure 15: eFlows Paddlewheel Design [10]

This design with a water column divider greatly reduced the problem of eddies forming

due to the constrictions of the pipe and was more laminar than the use of water jets. It used the

curves of the ends of the tank to change the direction of the water without adding turbulence.

This design used a paddlewheel to propel the water in the tank. The paddlewheel would be

placed in one end of the tank and rotate vertically, pulling water from the water column divider

and pushing it into the testing section. The paddlewheel would be relatively easy to construct. It

was planned to be six feet in diameter and made of aluminum sheets that were welded into the

paddlewheel shape as seen in figure 16.

Figure 16: eFlows Paddlewheel [10]


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This design was an improvement on the original design, but the paddlewheel would not

create a constant laminar flow. This paddlewheel design would create pulses and changing

pressure as the paddles passed the opening to the testing section, creating turbulence in the

testing area.

To solve this problem eFlow designed a Tesla Pump. The pump would also rotate

vertically, but instead of using paddles, it would use a series of disks, whose boundary layers

would pull the water along in a very laminar and constant fashion. The Tesla Pump would also

be easy to construct and could use the same materials as the paddlewheel. This design used 6

equally spaced disks connected by a central axle. Through research, eFlow determined that the

pump would also need four support rods running through the disks. Figure 17 shows eFlows

final design for the Tesla Pump [10]. The central axle can be seen in red and the support rods are

shown in green.

Figure 17: eFlows Tesla Pump [10]

The Tesla Pump would be located in the same position as the paddlewheel in the tank and

would pull water in the same direction. The design for the tank changed slightly however. It was

made simpler and easier to fabricate. The tank became box shaped and inserts were designed to

direct the flow as smoothly as in the previous design. eFlows final design can be seen below in

figure 18.


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Figure 18: eFlows Final Design [10]

eFlows report also included an analysis of the flow that would develop in the flume. This

analysis was done using two different softwares, Fluent and Gambit. This software determined

the direction and the velocity of water particles throughout the flume. This software was used to

develop the flow directing inserts to eliminate eddies and keep the flow constant. Figure 19

shows the velocity field that would develop in eFlows final design of the flume.

Figure 19: eFlows Fluent Analysis[10]

The eFlow team, led by Tom Bruger, then started construction of the tank. Tom

completed the fabrication of the tank bottom and walls in the Florida Tech Machine Shop. The

tank was made entirely of aluminum. C channels were used to create a structural frame over


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which aluminum sheets were welded. All welding was done by Mr. Bill Bailey in the machine

shop. Figure 20 shows the completed tank after assembly in the senior design area next to the

machine shop.

Figure 20: Fabricated Tank

eFlow also started construction on the center divider. The group ran out of materials and funding

however before the center divider could be completed. eflow began construction on the frame for

the center divider. The frame was constructed out of c channel and 3 of the 4 sheets of aluminum

have been welded to the top of the center divider. Figure 21 shows the center divider in this state

behind the machine shop.

Figure 21: Fabricated Center Divider


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3.0 Procedures

3.1 Customer Requirements

The first requirement of the flume is that it must produce accurate data during

experimentation. The flume must produce a laminar flow. Any experimentation done in the

flume will not be reliable if the flow is turbulent or if eddies form in the testing section.

Experimentation on submersed objects will also not be able to be done if a velocity gradient

develops through the water column. The flow needs to be closely, accurately and easily

controlled. Model testing and Reynolds similitude depend on accurately scaled free stream

velocities, and will not be accurate if the flow cannot be controlled. Testing will also be difficult

if it takes hours of slowly adjusting the speed of the Tesla Pump and measuring the velocity in

the testing section. The flume will need to have a suitable superstructure to allow testing to be

done in addition to a frame, which can accommodate any additional testing mechanisms that

need to be attached. Lastly scaffolding will be required to support students standing and moving

around on top of the flume during setup and testing.

The second requirement of the flume is that it must be portable. It needs to be able to be

moved without any excessive equipment or difficulty. This means that the flume must be able to

disassembled and reassembled without being damaged. The flume should also be able to driven

on a road in one piece. If testing needs to be done off campus it should be able to fit on a flatbed

truck or trailer. This means that the flume cannot be wider than 8.5 feet or taller than 14 feet as

these are the maximum dimension allowed on roads without special permitting.Finally the flume must be safe to operate. The flume needs to have safety measures to

prevent students from falling into the top of the flume, or having a body part of article of

clothing caught in a moving part. The flume will also need a mechanism to dump the water out

of the tank quickly in the event that a student is sucked in and trapped in the tank.

3.2 Engineering Specifications

As previously explained the flume will consist of 3 main components: the tank, the center

divider, and the Tesla Pump. All of the necessary calculations will be done to demonstrate that

all of the components have been designed to handle any stresses and loadings with an

appropriate factor of safety.

The tank has been entirely constructed from 6061-t6 aluminum. C-channels were welded

together to construct frames for the walls and bottom of the tank, 1/16 inch aluminum sheets


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were then welded over these frames to create a water tight reservoir. Figures 22 and 23 show the

completed tank after assembly

Figure 22: Computer Model of Tank

Figure 23: Tank as Fabricated

The tank will also have glass windows. These windows will be constructed by spacing 2

separate 48 by 30 by one eighth inch thick glass panes by a gap of one quarter inch. This gap will

then be filled with isophthalic resin. This resin greatly improves the strength of the windows

without the cost of a glass alternative such as plexiglass.

Originally the windows were put together using a wooden jig as seen in figure 24.


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Figure 24: Window Jig

This jig consisted of a 2x4 frame along the bottom and sides of the window with a one

half inch groove milled into the center so that the window and resin fit perfectly into the frame.

In addition to the frame, there were also two supporting plates screwed to the front and back of

the frame in order to prevent the glass panes from flexing. These support plates were constructed

of three eighths inch plywood with 2x4 ribs for rigidity.

In order to construct a window first both panes of glass were carefully cleaned, as shown

in figure 25.

Figure 25: Cleaning the Glass

Then quarter inch thick double sided foam tape was placed along the edges of one pane

of glass and the other pane was placed on top, as seen in figure 26.


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Figure 26: Placing Top Pane on Foam Tape

The bottom and side edges of the window were then sealed again using clear packing

tape. The window was then carefully placed in the wooden jig. Isophthalic Resin was mixed and

poured into the gap between the glass panes using a wide funnel until the gap was completely

full to the top edge of the panes of glass. The funnel was rectangular and was made of thin

cardboard taped together with clear packing tape.

Figure 27: Pouring Resin into Window

This method was tried 3 times and all attempts were unsuccessful. The windows

cracked because the hydrostatic pressure caused the glass to crack over any small imperfection in

the jig and the wood that made up the jig. A new method was then adopted after some further

research.


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The second method of creating windows involvedlaying the windows down on a slight

angle instead using a jig. The equation for hydrostatic pressure is depth multiplied by the specific

weight of the fluid. When the window is laid on its side the depth of the resin becomes very

small, causing the hydrostatic pressure becomes almost zero. This results in very little pressure

on the glass.

Figure 28: Refined Window Making Method

A cardboard funnel was made to ease the pouring of the resin in between the panes. It

was found that using three funnels at different locations along the top allowed the resin to be

poured in the window well before it gelled.

Figure 29: Cardboard Funnel


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The window was successfully made without cracking, however, the window was only

filled to three quarters fulldue to lack of resin. This proves the concept of making the windows

without a jig. These windows will be put into place by using 3MTM

Marine Adhesive/Sealant

5200. The 5200 will hold the glass into place in the tank without needing any holes to be drilled

in the glass or the tank for bolts. The 5200 will also act as caulk, sealing the windows to the tank,making them watertight.

The center divider will be constructed the same manner as the tank, it will have a C-

channel frame with aluminum sheets welded to the top and bottom. The center divider will be

bolted to the sides of the tank using half-inch stainless steel bolts, this will improve the rigidity

of the tank under the load of the water pressure. It will prevent the tank from bowing outwards in

the center and potentially damaging the glass windows. The center divider will be placed flush

against the Tesla Pump in the tank and raised 26 inches from the tanksbottom. Depending on

the availability of funding and time, a finger system will be attached to the end of the center

divider. The fingers will be constructed of C-channels and aluminum sheets. They will extend in-

between the disks toward the central shaft in order to completely separate the two directions of

flow. Figure 30 shows the center divider drawing in pro/E and figure 31 shows the divider

(outlined in blue) bolted into the tank.

Figure 30: Computer Drawing of Center Divider


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Figure 31: Computer Model of Center Divider in Tank

The Tesla Pump will be constructed of 6 fiberglass disks with an 8 inch gap between each

disk. These disks will be keyed to a 2-1/4 inch diameter 6061-t6 aluminum shaft. This shaft will

rotate in two stainless steel bearings. These bearings will be held in place by an aluminum frame

that houses the Tesla Pump. A cover will be welded on to protect the motor from being splashed

as seen below in figures 32.

Figure 32: Computer Model of Tesla Pump

Each disk will be made up of 8 foam preforms fiber glassed together and finished in resin

and gelcoat. The preforms were made at Comsys using a mold fabricated out of wood to the

specifications seen in figure 61. The mold is divided into a top half and a bottom half as seen in

figure 33.


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Figure 33: Preform Mold

Each half of the mold is first lined with a precut pattern of two ply cloth. This cloth iscomprised of 45x45 fiberglass cloth that is backed by a tightly woven polyester cloth as seen in

figure 34.

Figure 34: Mold Lined with Fiberglass

The fiberglass cloth is placed against the mold so that it can later absorb resin during the

final construction of the disk. The polyester cloth adheres to the foam inside the preform, this

polyester cloth is very fibrous which allows for a strong bond between the polyester cloth and the

foam and keeps the foam from expanding into the outer layer of fiberglass cloth. After the cloth

is placed in each half of the mold and pressed tightly into the corners as seen in figure 35.


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Figure 35: Lining of Mold with Fiberglass

The bottom half of the mold is filled with a two part closed cell expanding foam.

Comsys system is computer controlled so that the temperature and mixture of each part of the

foam is closely monitored. This system also calculates the exact amount of foam required to fill

each mold and meters out that amount so that the technician cannot overfill or under fill the mold

as seen in figure 36.

Figure 36: Injection of Foam into Mold

Once the bottom half of the mold has been filled with foam the top half is quickly moved

into place and clamped down tightly onto the bottom half as seen in figures 37 and 38.


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Figure 37: Closing of the Mold

Figure 38: Allowing Foam to Cure

The foam expands and sets up within 10 minutes. Once the foam is cured, the mold is

unclamped and the preform is removed from the mold as seen in figure 39. The next preform can

then be made.

Figure 39: Finished Preform in Mold


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In order to combine all the pieces into one disk, the sides of the preform have to be

wetted out and joined together with a piece of fabric in between them. A mount is made to hold

the pie pieces into place; this will not only make sure the pie pieces are in the right spot but will

also help to make it easier to flip the disk during the fiberglass phase.

Figure 40: Wooden Mount for Telsa Disks

The entire disk will be squeezed together by placing a ratchet strap around the outer edge

of the disk and tightening. This will allow for all the pieces to move into its proper place and also

allow for the hole in the middle to be a perfect circle.

Figure 41: Tightening the Ratchet Strap

All the joints need to be sanded flush with the disk in order for the next layers of fabric to

lay flat and keep the curvature of the disk. A DA sander should be used with a coarse grit to

remove excess fiberglass from the joints. Proper safety equipment should be worn at all times.


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Figure 42: Sanding Joints

The surface of the disk is then wetted out and fiberglass, in strips of 72 inches long and

22 inches wide, is wetted out and placed in across the disk. The disk is then flipped and the

process is repeated. This whole process is repeated, rotating the disk, until the entire disk is

covered. The disk is then perfected by filling the low spats with Bondo. Using a long aluminum

rod, Bondo is spread evenly around the disk making a perfectly smooth and consistent surface,

filling any holes that might cause the disk to wobble.

Figure 43: Smoothing the surface of the disk

The entire disk is then spray painted, this will show where the low spots on the surface of

the disk are. This is accomplished by sanding after the paint is dry leaving the only paint in the

low spots. Once this is accomplished it can be concluded that the surface of the disk is as perfect

it can be, yielding a conclusion that there will be no wobble during operation.


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Figure 44: Disk after being Spray Painted

Once the first disk was completed, a flange made of plywood pieces was attached to theedge of the disk along the entire circumference. The plywood pieces were hot glued into place.

Figure 45: Gluing the Flange to the Disk

The wooden flange was then covered in packing tape. One of the sides was then covered

with mold release wax. 7 coats of mold release wax were applied, by covering the disk in wax,

waiting 5 to 10 minutes and then removing the wax and waiting 30 minutes between coats.

Once the disk was thoroughly waxed, gel coat was sprayed even on in a .24 linear

mils thick layer.


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Figure 46: Spraying Gel Coat on the Disk

After the gel coat started to cure, the disk was coated in resin and a layer of mat

fiberglass was laid down. Once the resin hardens, 3 more layers of fiberglass are added one at a

time, with the second being another layer of mat and the final two layers being normal cloth.

Figure 47: Layering fiberglass cloth on the disk

Once the disk has 4 layers of fiberglass on it, preform beams are then resined on to

provide structural support. The joints of the beams are covered with strips of fiberglass to help

prevent hinging.


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Figure 48: Finished Mold on Disk

After all of the resin hardened completely, the mold was popped off the disk. The disk

was then repaired any place the Bondo was chipped and the entire process was then repeated to

make a second mold. Any excess fiberglass was cut off around the flange and the molds were

then wet sanded and buffed to a high shine.

Figure 49: Removing Excess Fiberglass


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Figure 50: Buffing the Disk

The molds can now be used to make disks in 1-2 days versus hand lay-up which takes 5-7

days. Although the molds will save a lot of time and ensure better looking disks, making each

one will still be a multistep process. First, the molds need to be coated with 7 layers of mold

release wax then coated in a layer of gel coat 24 mils thick. Next, layers of fiberglass cloth will

be wetted out with resin and laid over the length of each mold so that the cloth fans out just

barely overlapping on the outer edge of the mold and completely overlapping in the center of the

mold. Next, each preform is wet out with resin and one strip of resined cloth is placed in between

each preform. The preforms are arranged in one half of the mold and the other half of the mold is

placed on top and the flanges are clamped down. The disk is let cure for 8-12 hours. The disk is

then popped out of the mold and it is repeated for the other disks.

There will be a 23.5 horse power, three phase motor bolted to the top of this frame. The

frame will have a splash guard between the motor and the pump disks and a housing over the

motor to ensure that all of the electronic components stay dry. The motor will be connected to

the shaft of the Tesla Pump by a chain drive and sprockets.

The method for attaching the disks to the axle is by using two flanges, placed on both

sides of the disk. Welding a quarter inch pipe to a quarter inch thick plate makes these flanges.

The plate has four holes drilled through allowing for four bolts to go through the flange, into the

disk, and securing to the flange on the other side. On the shaft of each flange are two holes for

setscrews, this allows for the flange to be secured to the axle, preventing the disk from moving

laterally and preventing the disk from slipping as the shaft spins.


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Figure 51: Flange to Connect Disk to Shaft

A three phase electric motor was donated to the NARWHALEs team by the waves lab. It

is a 23.5 horse power three phase motor. The motor can be seen in figure 54. Because it is a three

phase motor, it can be connected to a controller and a computer. The controller can also be seen

in figure 54. This controller takes input from an operator and controls the ameprage and voltage

being sent to the motor to presicely control the revolutions per minute of the shaft. This will

allow the speed of the water in the flume to be closely controlled.

Figure 52: Motor and its ControllerTo connect the motor to the shaft and disks, a chain drive and sprockets will be used. The

sprockets will allow a gearing ratio to be set up between the motor and the disk shaft. This is

important because the fan of the motor runs directly off of the shaft of the motor and needs to

spin at 1500 rpms. Using a small sprocket on the motor and a large sprocket on the shaft the

motor will spin faster than the disks. This will allow the flume to be run at low speeds without

over heating the motor. Figure 55 shows a chain drive used to create a gearing ratio on the

electric motor that drives the wave generator in the wave tank.


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Figure 53: Example of a Chain Drive System

In order to use a chain drive a motor mount needs to be constructed that can tension the

chain. The motor being used is meant to be a vertical motor and has its bolt pattern on the face of

the motor. The motor was origionally bolted to a steel plate that allows it to be held horizontally

by the post in the waves lab. This plate will be used with the motor mount to suspend the motor

between two beams. The motor mount was constructed of two aluminum plates welded to

eachother at a right angle. One plate has slots milled into it that match the bolt pattern of the

motor and will allow it to slide to tension the chain. The other plate has 4 tapped wholes through

wich bolts are inserted and turned to lift the steel plate bolted to the motor. This will raise the

motor through the slots and tension the chain while keeping the motor supported and aligned.

Figure 54: Motor Mount

To protect the motor from weather we had to build a motor housing. The housing is

constructed with a 2 x 4 frame with 1 x 4 slates. The slates allow air flow when the motor fan

turns on yet protects it from rain. The housing will rest on C channels around the motor. It was

designed so a door can be opened and the housing can slide back to allow full access to the

motor for easy inspection and maintenance.


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Figure 55: Construction of Motor Housing Sides

Figure 56: Motor Housing Under Construction

Figure 58 shows the flume as it will look when it is completed and assembled, with the

exception of the motor and its housing. The center divider is in place to separate the flow and the

Tesla pump is in the cage at the one end to circulate the water.

Figure 57: Final Assembly


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The Flume is located on a concrete slab behind the Link building. This location has easy

access to water and electrical hook ups. There will be enough room around the flume to safely

operate without constrictions. This location also provides a fence to protect the flume from being

damaged by foreign objects. The road, seen below in figure 59, will provide easy access for

models to be tested as well as enabling the flume to be moved as needed.

Figure 58: Final Location

3.3 Function Decomposition of Structure

The tank is 25 feet long over all, 8 feet wide and 8 feet tall. These dimensions were

chosen to allow it to be easily transported on a road. The c-channels that make up the frame all

have the same cross section. They have a web of 4 inches by 5/16 inches and flanges of 1

inches by 5/16 inches. Figure 59 is a drawing generated in Pro/E that shows all of the spacing

between the C-channels and the overall dimensions of the tank. These dimensions are not exactly

the dimensions that the eFlow team designed, but are what eFlow has actually fabricated. After

construction was finished, measurements were taken to be able to accurately draw the tank and

design the systems that have yet to be placed inside it. All dimensions are in inches.


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Figure 59: Final Drawing of Tank

The center divider has two aluminum angles that run the length of the center divider. The

flanges are 3 inches wide and 5/16 inches thick. C-channels were then welded to the bottoms of

these angles. Two differently sized C-channels were used. The larger has a web of 4 inches and

flanges of 2 inches, and the smaller C-channel has a web of 2 1/8 inches and flanges of 1

inches. Figure 60shows the dimensions of the center divider and the locations of each C-channel.

All dimensions are in inches.


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Figure 60: Final Drawing of Center Divider

Each Tesla disk will be 6 inches in diameter with a 3 inch hole in the center for the

central shaft to fit through. The disks will be keyed to the shaft. The disks will be 6 inches thick

in the center and will taper down to 2 inches think at the edge. This shape was chosen to give the

disks a higher modulus of inertia at the center where the bending moment and stress will be the

highest. The figure61 below shows the dimensions of the Tesla pump disks.

Figure 61: Drawing of one Disk


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4.0 Results

As seen below we have carefully calculated the pressure on the disks, the size of motor we

need, diameter of the axle, pressure on the windows, how much resin and adhesive we need for

the windows, and the boundary layer.

Pressure on a Disk

Motor Size Needed


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Diameter of Axle

Pressure on the Windows

M=3895

Tensile strength of glass = 467MPa

With a SF of 10

Resin needed for the windows


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51

Two plate glass sides

With an of resin in between

( )

Adhesive needed for the windows

( )

Boundary Layer

Total Allowable Load in Motor Mount Beams


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5.0 ConclusionThe NARWHALE flume has been designed to test ship models and underwater vehicles

as accurately as possible. It has been designed to re-circulate water to create a laminar flow in the

test section. This will allow testing throughout the length of the test section and at different

depths in the water column. The flume will be portable so that it can be moved at any time if

necessary. The Tesla Pump and tank that have been designed meet all of the engineering

requirements and specifications. It has been designed with appropriate factors of safety and will

be able to withstand the forces and stresses that develop in the individual members of the flume.

The flume will be a major asset to DMES and Florida Institute of Technology as a whole. The

flume has the potential to improve research and academics in many fields and majors.

6.0 Recommendations

The NARWHALE group recommends that the flume project be continued next year. To

help correctly channel the flow and reduce turbulence, a flow return should be constructed and

placed at the opposite end of the tank from the pump. The flow return should be a sheet of

aluminum welded into a curve to change the direction of the water gradually and smoothly.

There will be much design work and engineering to be done after the flume has been built. The

flow through the flume will need be experimented on and fine-tuned to ensure the most accurate

results. It will need to be tested throughout the tank to see if eddies or velocity gradients form.

While computer programs such as Fluent are a great tool in designing, they cannot be expected

to be perfectly accurate in practice, as there are too many factors to take into account.

Testing apparatuses and scaffolding will also need to be constructed to accommodate

experiments and students. As the flume begins to be used in research improvements needing to

be made may become evident in different areas and systems. Brackets for instrumentation could

be constructed. For instance, the slides required for mounting wave gauges could be installed to

allow the monitoring of the free surface elevation possible during testing. A platform could be

built over the top of the flume to accommodate moving models in and out of the flume and

prevent people or debris from falling into the tank. The flume is currently 8 feet tall. This will

make simply lifting test subjects over the side and placing them in the water very difficult.

Finally improvements to the design will undoubtedly be made in the future, as more

funding becomes available to future senior design teams. The sheer size of the flume and the

materials that it is constructed of make building the flume more expensive and time consuming

than many other senior design projects on campus.


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Appendixes

A -- References:

[1].AquaBioLab, AquaBioTechInc, Apr. 2011. [Online]. Available:

http://www.aquabiolab.com/en/products/flumes_systems/benthicflume.shtml, [Accessed: Apr. 8,

2012].

[2] B Munson.Fundamentals of Fluid Mechanics. 6th ed. U.K.: John Wiley and Sons, 2010.

[3] C Cawood, NewMethod for the Hydrodynamic Evaluation of Ship Hull Coatings. M.S.

Dissertation, Department of Marine and Environmental Systems, Florida Inst. of Technology,

Melbourne, Fl, 2009.

[4] DiscFlo Disc Pumps. DiscFlo Corporation. 2011[Online]. Available:

http://www.discflo.com/, [Accessed: 10 April. 2012].

[5] F Beer et. al. Mechanics Of Materials. 6thed. NY: McGraw-Hill, 2012

[6] Flume. Department of Physical Education, University of Otago, New Zealand. [Online].

Available: http://physed.otago.ac.nz/about/virtual.html, [Accessed: Apr 12, 2012].

[7] J Nelka. Evaluation of a Rotating Disk Apparatus: Drag of a Disk Rotating in a Viscous

Fluid. Naval Ship Research and Development, 1973.

[8] Nikola Tesla Disk Turbine Pump. RexResearch.[Online]. Available:

http://www.rexresearch.com/teslatur/teslatur.htm, [Accessed: Apr. 10, 2012]

[9] N Tesla, Tesla Turbine, U.S. Patent 1 061 206, Jan. 17, 1911.[10] T Bruger et al, eFlow Final Report, Florida Institute of Technology: Melbourne, FL,

2011.

[11] T Clayton et. al. Engineering Fluid Mechanics. Massachussettes: John Wiley and Sons,

2001.

BResources

Machine Shop Equipment

Bill Bailey

Jim Hayes

Greg Peebles

Dr. Ronald Reichard

Dr. Stephen Wood


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Dr. Steven Jachec

Dr. Robert Weaver

Dr. Geoffrey Swain

Bill Battin

C -- Safety Plan

Hazard Analysis

Material Description

When working on the center divider we will need to weargloves to prevent cutting our

hands while handling the sheets of aluminum. When Bill is welding the aluminum sheets to thecenter divider frame he will need to wear a face mask and gloves for protection. We will need to

wear safety goggles when drilling holes in the aluminum frame to prevent aluminum chip fromflying into our eyes.

When making the windows we will need a well-ventilated area or respirators while

pouring resin into the glass pans supported by a jig. We will also need gloves when handling theglass windows to prevent cutting our hands.

The Tesla Pump will be powered by a 23.5 horsepower electric motor. The motor will sit

above the Tesla wheel on a platform on top of the flume frame. We will consult with Jim Hayes amaster electrician about the best placement and type of motor for our flume. The motor will run a

gear connected to another gear by a chain which will spin the tesla wheel shaft. Possibly hazards

include the pulley breaking, electric shock, or fire. The moving pulley could grab foreign objectsor people causing damage or injury. Water and grease mixing could cause environmental hazardsor health risks if drained improperly.

When working on the Tesla Pump we will be dealing with objects getting stuck in thedisks as it rotates. When constructing the disks we will be handling resin and fiber glass cloth. To

protect ourselves we will work in a well-ventilated area or wear respirators. We will be wearing

gloves to protect our hands from the hazardous materials.

Environmental Impact Analysis

Waste must be disposed of in accordance with federal, state and local environmentalcontrol regulations. Please see attached MSDS sheets for each material listed below.

Aluminum

MSDS: http://www.sciencelab.com/xMSDS-Aluminum-9922844

Water


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MSDS: http://www.sciencelab.com/msds.php?msdsId=9927321

3M Adhesive 5200

MSDS: http://www.shopmaninc.com/pdf/adhesives/3m5200.pdf

Glass

MSDS:https://www2.itap.purdue.edu/msds/docs/3864.pdf

E Glass

MSDS:http://www.advanced-plastics.com/msds/F05_090611.pdf

Polyvinyl alcohol

MSDS:http://avogadro.chem.iastate.edu/MSDS/polyvinyl_alcohol.htm

Gel Coat

MSDS:http://www.nacomposites.com/literature/msds.html

Resin VE8123 Corezyn

MSDS:

http://www.plasticmaterials.net/msds/resin2_msds/789-7775%20VINYL%20ESTER%20RESIN.PDF

Hi-Point 90 Catalyst

MSDS:www.foamez.com/pdfs/MEKMSDS.pdf

Isophthalic Resin

MSDS:http://www.fibglass.com/pdfs/msds/aropol%20m7392%20iso.pdf

Bondo

MSDS: http://www.jamestowndistributors.com/userportal/pdfs/MSDS/bondo/272.pdf

Human Safety Analysis

Personal Protection Equipment

Several types of Personal Protection Equipment (PPE) will be used in this project. The first

and most obvious PPEs are the use of safety glasses and closed toe shoes. While using drills or

saws, safety glasses are a must to protect the eyes from any small pieces that may fly up whiledrilling or sawing materials. Also, closed toe shoes must be worn at all times when dealing with

heavy materials that could crush or cut ones toes. Next, gloves and safety masks for welding must
https://www2.itap.purdue.edu/msds/docs/3864.pdfhttps://www2.itap.purdue.edu/msds/docs/3864.pdfhttps://www2.itap.purdue.edu/msds/docs/3864.pdfhttp://www.advanced-plastics.com/msds/F05_090611.pdfhttp://www.advanced-plastics.com/msds/F05_090611.pdfhttp://www.advanced-plastics.com/msds/F05_090611.pdfhttp://avogadro.chem.iastate.edu/MSDS/polyvinyl_alcohol.htmhttp://avogadro.chem.iastate.edu/MSDS/polyvinyl_alcohol.htmhttp://avogadro.chem.iastate.edu/MSDS/polyvinyl_alcohol.htmhttp://www.nacomposites.com/literature/msds.htmlhttp://www.nacomposites.com/literature/msds.htmlhttp://www.nacomposites.com/literature/msds.htmlhttp://www.plasticmaterials.net/msds/resin2_msds/789-7775%20VINYL%20ESTER%20RESIN.PDFhttp://www.plasticmaterials.net/msds/resin2_msds/789-7775%20VINYL%20ESTER%20RESIN.PDFhttp://www.plasticmaterials.net/msds/resin2_msds/789-7775%20VINYL%20ESTER%20RESIN.PDFhttp://www.foamez.com/pdfs/MEKMSDS.pdfhttp://www.foamez.com/pdfs/MEKMSDS.pdfhttp://www.foamez.com/pdfs/MEKMSDS.pdfhttp://www.fibglass.com/pdfs/msds/aropol%20m7392%20iso.pdfhttp://www.fibglass.com/pdfs/msds/aropol%20m7392%20iso.pdfhttp://www.fibglass.com/pdfs/msds/aropol%20m7392%20iso.pdfhttp://www.fibglass.com/pdfs/msds/aropol%20m7392%20iso.pdfhttp://www.foamez.com/pdfs/MEKMSDS.pdfhttp://www.plasticmaterials.net/msds/resin2_msds/789-7775%20VINYL%20ESTER%20RESIN.PDFhttp://www.plasticmaterials.net/msds/resin2_msds/789-7775%20VINYL%20ESTER%20RESIN.PDFhttp://www.nacomposites.com/literature/msds.htmlhttp://avogadro.chem.iastate.edu/MSDS/polyvinyl_alcohol.htmhttp://www.advanced-plastics.com/msds/F05_090611.pdfhttps://www2.itap.purdue.edu/msds/docs/3864.pdf


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be at hand. While welding, it is vital that one wears the proper gloves and mask in order to not get

burnt or blinded from the welder respectively. Following that, a respirator must be worn whileusing materials that have harmful chemicals such as paints or marine grade coatings that prevent

corrosion.

General Work Safety

Any team member working on the project will be machine shop certified. This will ensure that theworking environment is safe and that each member conforms to the safety regulations set forth by

the machine shop. This will ensure the teams safety and success.

Anytime a member is in the machine shop or working on the project, the member will wear the

appropriate protection equipment as required by the MSDS sheet per material.

To comply with the

above regulation, each team member will wear respirators when the MSDS sheet requires. Safetyglasses will be worn at all times to protect the eyes.

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Flume Final Report 2012

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