Friday, May 14, 2004 SOFC Durability Test Stand 1
Team 04032Delphi Corporation
Solid Oxide Fuel Cell Durability Test Stand
•John Bagby
•Joshua Gannon
Mechanical Engineers Electrical Engineers
•Michael Scholl
•Gregory Tyminski
•David White
•Wai Meng Ng
•Richard Yang
Faculty Mentor•Margaret Bailey, Ph.D., PE
Delphi Contact•Chris Mergler
Friday, May 14, 2004 SOFC Durability Test Stand 2
Subgroup Structures
Test Stand
In
OutStructure
SOFC Controls
Air
Start-UpPower
Fuel
NG
Diesel
Gasoline
Heat
Sensors
Lab
Power
Data
Exhaust
Top
80/20
Enclosure
Safety
Sides
Mind Map
DurabilityStand
StandStructure
Inputs ControlsOutputs
AirStart-upPower
ExhaustFuel
NaturalGas
PowerData
DieselGasoline
SOFCInternal
Controller
Safety
DataCollection
Logic
AlgorithmsFuel
Control
FuelGas
PowerTemps Pressure
Enclosure Supports
ShelvesExhaust
Side
Lexan® Sides
Work Breakdown Structure - Subsystem Flowchart
(a) (b)
Friday, May 14, 2004 SOFC Durability Test Stand 3
Stand
Preliminary Design
1.5” x 1.5” 80/20 extruded aluminum built 36” tall
Double Anchor Bolt Fasteners for assembly
4 lengths 80/20 top rails supporting top plate
Post PDR Suggestions
32” height of stand
Elimination of 4 supporting 80/20 top rails
Final Decisions2” x 2” 80/20 extruded aluminum used due to in-stock supply
80/20 corner brackets and joining plates used for assembly due to in-stock supply
32” height of stand
Top rail elimination
Friday, May 14, 2004 SOFC Durability Test Stand 4
Stand and FEA
1
MN
MXX
Y
Z
-.003114
-.002768-.002422
-.002076-.00173
-.001384-.001038
-.692E-03-.346E-03
0
MAY 12 200411:17:58
NODAL SOLUTION
STEP=1SUB =1TIME=1UY (AVG)RSYS=0DMX =.003115SMN =-.003114
•Maximum Deflection under 700lb Load: 0.003in
Friday, May 14, 2004 SOFC Durability Test Stand 5
Enclosure
Preliminary Design80 / 20 Extruded Aluminum, 1” x 1” Cross Section
Supporting StructureCast Acrylic Plexiglas
Toggle Clamp Attachment for enclosure removalExcellent Clarity150 degree F tolerance
Firewall1850 degree F tolerance
Rubber SealFulfills airtight requirement
Aluminum PlateDue to high temperature requirement at exhaust outlet
Post PDR SuggestionsHinges for enclosure opening
Reduces manual lift of enclosure to supporting position on the stand base
Top Exhaust for CO startup leakExtra air draw through enclosure to reduce CO emissions into the room
Movable position of top plate within enclosure
Gives better inline positional placement of exhaust of SOFC to enclosure exhaust opening
Friday, May 14, 2004 SOFC Durability Test Stand 6
Enclosure
Final Decisions Hinges are to be used to open enclosure with support braces for a
propped position on stand No Top Exhaust addition
Relay on sensors and Labview within enclosure to shutdown stand if necessary
Movable plate within enclosure Top plate is anchored at its vertical position Enclosure hood is vertically movable
• Manual disassembly and reassembly of supporting 80/20 for vertical movement of enclosure
• Enclosure movement provides robust placement of SOFC in comparison to hood exhaust outlet
Friday, May 14, 2004 SOFC Durability Test Stand 7
Fuel Delivery System
Fuel Supply Delivery System System supplies natural
gas/diesel/gasoline fuels to SOFC. Refueling is accomplished without
interrupting the fuel flow to the SOFC. Fuel Pump supplies liquid fuel at 500kPa
to fuel injector. Redundant Automatic shutdown safety
feature.
Friday, May 14, 2004 SOFC Durability Test Stand 8
Swagelok Components
Warren Rupp Sandpiper II Diaphragm Pump
McMaster-Carr High Pressure Fuel Tanks
Fuel Delivery System
Body Side
Body Side
Body Side
Body Side
PumpFuel Filter
Fuel Tank #1
Pressure GaugeFuel Tank
SOFC
Purge Res.
V-1
Air Line From Gauge Block
V-2
V-3
V-4
N2 Line From Gauge Block
N2 Line From Gauge Block
V-5
T-2 V-6
V-8
P-1
V-9V-10
V-11
Pressure GaugeFuel Tank
V-12Fuel Tank #2
C-2C-3
C-4C-5
T-1
T-3
T-4
T-5 T-7T-6
Element
C-6
P-7
P-8
P-9
P-10
P-11P-12
P-13P-14 P-15
P-16
P-17P-18P-19
P-20
P-21P-23
P-24 P-25
P-26
P-27
P-28
C-22
V-13
V-14
DC powerSolenoid
DC Start-UP Power
DC powerSolenoid
ACWIRE TBD
P-36
P-37
Friday, May 14, 2004 SOFC Durability Test Stand 9
ControlsComponent Interface
Labview 6.1
The main view of the controls were already developed by Delphi. Our task was to integrate what we had with the given components.
Enclosure data, fuel pump enable and enclosure warnings.
E-stop is to be tied in with the e-stop sequence for SOFC unit.
Friday, May 14, 2004 SOFC Durability Test Stand 10
Data collection for enclosure’s thermocouples and gas sensors.
Detection of warning & e-stop violations.
Data logging writes to a new file each day.
Stand DAQ VI can be incorporated into Main VI as a sub VI with one input and two outputs.
Input for initialization
Two outputs for data values and warning signals.
Data Acquisition
Friday, May 14, 2004 SOFC Durability Test Stand 11
Financial Summary
REQ Number Subtotal (Less Tax) REQ Number Subtotal (Less Tax) REQ Number Subtotal (Less Tax)1 $735.80 10 $4,550.00 17 $629.003 $436.20 11 $574.08 18 $2,853.004 $518.30 12 $323.70 19 $17,150.005 $995.10 13 $71.46 20 $425.007 $408.00 14 $447.52 21 $3,830.008 $1,163.50 15 $512.32 22 $44.809 $258.60 16 $54.94 6* $2,000.00
* Quote Needed
Fuel Total $4,515.50 Stand Total $6,534.02 Controls Total $26,931.80
Subtotal $37,981.32
ControlsFuel Delivery Stand
Components Removed From Budget By Delphi Corporation•Many Swagelok, exhaust and computer components, stocked in house•Field Point Modules $4.2K•$12K Load Bank Replaces $17K Load Bank •Gas Sensor System $4.5K
Friday, May 14, 2004 SOFC Durability Test Stand 12
Tasks Outstanding
Finalize and debug Controls & DAQ Virtual Interface
Full installation into Laboratory environment: Plumb Air, NG, Exhaust lines
Friday, May 14, 2004 SOFC Durability Test Stand 13
Thank You:
R·I·T
Margaret Bailey, Ph.D., P.E.
Alan Nye, Ph.D.
Delphi Corporation
Mr. Chris Mergler
Mr. Chris DeMinco
Mr. Anthony DeRose
Mr. Kristian Whitehouse
Friday, May 14, 2004 SOFC Durability Test Stand 14
Questions