Pre-positioned Expeditionary Assistance Kits (PEAK) Including

Pre-positioned Expeditionary Assistance Kits (PEAK) Including: Power Generation, Robust Water Purification, Communication, and Cooker Systems

MS4 Final ReportPrepared by:

Era RaizadaEric Gingrich

Waleed Al-TaieRoslayn WarnerBruce Slykhouse

Jahirul Chowdhury

Department of Mechanical Engineering Wayne State University

Submitted to Professor Dr. Lai in partial fulfillment of the requirements of:

ME 4300 Thermal-Fluid System Design

Date: December 13, 2010

Executive Summary

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The United States Department of Defense has developed a project with the goal of developing a Pre-positioned Expeditionary Assistance Kit (PEAK), supplying essential services in times of crises. The PEAK includes: power generation, water purification, communication and a cooking system. The kit must leverage existing technology and make maximum use of commercial, off-the-shelf (COTS) technology. Power must be generated through renewable resources.

Warrior Innovative Design (WID) has completed four milestones (MS) to complete this project. MS1 includes an investigation of the problem statement to develop specifications, criteria, and constraints. WID developed and analyzed four comparable designs in MS2 that could meet the needs of a PEAK. Two different decision matrix processes were used to select the final design in MS3. The first decision matrix with yes or no entries was applied to all four designs to find out whether or not each design met the demands of the specifications and constraints. The second decision matrix was called a Pugh Analysis, with number entries applied to all designs using these criteria. The weighing percentage was assigned a numerical value to each category of criteria used to justify the decision making process.

Design 1 was confirmed by the Pugh analysis to be the best design. The descending order was Design 4, Design 2, and Design 3. Final design, Design 1, has an ultraviolet water purifier, a solar cooker and a 1 kW solar power generator. The alternative components can be found under Section 2 of this report under the Alternative Design Concepts section. The Failure Mode and Effect Analysis (FMEA) method was used for conducting the safety analysis in MS3.

The improvement of the final design was developed in MS4. WID worked on improving the final design in weight and volume since MS3. The overall cost and weight of the final design is approximately US$37,040.5 and732.6 lb, respectively.

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Table of Contents1. Problem Statement.......................................................................................................................6

1.1 Background.....................................................................................................................61.2 Specifications..................................................................................................................61.3 Constraints.......................................................................................................................71.4 Criteria.............................................................................................................................71.5 Testable Requirements....................................................................................................7

2. Alternative Design Concepts.......................................................................................................82.1 Significant Features of the Alternative Designs..............................................................82.2 Overall Schematics of Subsystems and Components.....................................................9

2.2.1 Design 2..........................................................................................................92.2.2 Design 3........................................................................................................142.2.3 Design 4........................................................................................................17

2.3 Energy and Environmental Analyses............................................................................182.3.1 Design 2........................................................................................................182.3.2 Design 3........................................................................................................192.3.3 Design 4........................................................................................................19

2.4 Packaging Breakdown...................................................................................................202.4.1 Design 2........................................................................................................202.4.2 Design 3........................................................................................................202.4.3 Design 4........................................................................................................21

2.5 Economic Analyses.......................................................................................................222.5.1 Initial Purchase Cost.....................................................................................222.5.2 Annual Maintenance Cost.............................................................................22

3. Decision Making & Presentation of the Proposed System........................................................233.1 Technical Analysis........................................................................................................23

3.1.1 Water Purifier...............................................................................................233.1.2 Solar Cooker.................................................................................................243.1.3 Solar Power System......................................................................................25

3.2 Decision Making Analysis............................................................................................263.3 Final Design: Overall Schematics of Subsystems and Components.............................273.4 Mass and Energy Flow of Subsystems and Components..............................................283.5 Packaging and Installation............................................................................................303.6 Materials and Economic Analysis.................................................................................32

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3.6.1 Initial Purchase Cost.....................................................................................323.6.2 Annual Maintenance Cost.............................................................................32

3.7 Safety Analysis of the Final Design..............................................................................323.7.1 Water Purifier...............................................................................................323.7.2 Solar Cooker.................................................................................................333.7.3 Power Generation: Solar Power....................................................................34

3.8 Features & Operations...................................................................................................384. Design Analysis & Verification.................................................................................................39

4.1 Photovoltaic Power System Analysis............................................................................394.2 Solar Cooker Design Analysis......................................................................................474.3 Solar Cooker Verification.............................................................................................47

4.3.1 Model Conditions.........................................................................................484.3.2 Material Properties........................................................................................484.3.3 Boundary Conditions....................................................................................494.3.4 Calculations..................................................................................................49

5. Appendix....................................................................................................................................515.1 Appendix I: Water Purifier............................................................................................51

5.1.1 Minimum UV Light to Destroy Contaminates.............................................515.1.2 Water Purification System Design...............................................................51

5.2 Appendix II: Solar/Wood Cooker.................................................................................535.2.1 Irradiation Map of Africa (PVGIS, 2008)....................................................535.2.2 Solar Cooker Efficiency...............................................................................535.2.3 Solar Cooker Performance Factor................................................................535.2.4 Solar Cooker Cost.........................................................................................535.2.5 Solar Cooker Weight....................................................................................545.2.6 Solar Cooker Calculation..............................................................................545.2.7 Electric Generation Flow Rates (Calculations)............................................54

5.3 Appendix III: Power Generation...................................................................................555.3.1 Solar Power System (Sample Calculations).................................................555.3.2 Wind Power System (Sample Calculations).................................................565.3.3 Solar-PV System Location Parameters.........................................................575.3.4 Wind-Power System Location Parameters...................................................585.3.5 Power Generation: Cost, Packaging, and Power Curves:............................58

5.4 Appendix V: Technical and Environmental Analysis (Design 1)................................635.4.1 Thermal-Fluid Specifications.......................................................................63

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5.4.2 Environmental Considerations......................................................................675.5 Appendix VII: Public Awareness/Community Outreach Plan......................................685.6 Appendix VI: Complete Maintenance Information and Costs.....................................69

6. References..................................................................................................................................76

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1. Problem Statement1.1 BackgroundDesign a pre-expeditionary assistance kit (PEAK) that includes: power generation, water purification, communication, and a cooking system. Used in a time of crises, PEAKs will help authorities in theater provide critical services. The kit must leverage existing technology and make maximum use of commercial, off-the-shelf (COTS) technology. Power must be generated through renewable resources. The kit must support 20 people in a climate similar to East Africa.

1.2 SpecificationsThe following table will explain the overall PEAK system design specifications. The detailed specifications for each design will be listed under each specific component.

Location East AfricaOverall Power Generation

Must be relying on the renewable resources

Electricity 110V / 220V and 60 HzPower Consumption 1kW (Max)

Water Purifier Filtered contaminants Microorganisms > 0.5 microns; Viruses < 0.5 micronsPolishing Carbon FiltrationRemove Taste, Odor, Organic compounds and bacteriumPower Source ElectricalWater Supply 370 L water per day

CookerPower Supply Sun or BiomassSecondary Power Supply Electrical Heating CoilsHeating Capacity 6 kg of water to 100oC in less than 4 hrs

Table 1: Overall Specifications for All PEAK System Designs

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1.3 ConstraintsCompleted kit and consumables must fit on a single 463L Cargo Air Pallet for air deployment with usable space of 84 in x 104 in x 104 in. The total weight of the system cannot exceed 500 lbs and must be packaged to be towed by vehicle a LTAS-B military truck for land deployment. The kit must be setup and working in 24 hours of time. All parts of the kit must be able to withstand climate similar to East Africa with temperatures ranging from 20 - 105⁰F. All elements must be able to withstand heavy rain and high humidity.

1.4 CriteriaThe final design of a PEAK will be composed of individual components. The following criteria will be used when evaluating different components. Criteria towards the top of the list will be given higher priority. Percentages for each criterion are listed. More emphasis will be put on reliability, durability and packaging because PEAKs are used in a military environment where resources may be limited. The weighted criteria for the complete system can be found below:

I. Best packaging and transportability (25%): a. Smallest size -- 10%b. Lowest weight -- 15%

II. Environmental consideration (20%):a. Best durability for environment -- 10%b. Lowest environmental impact -- 10%

III. Consumption Efficiency (20%)a. Lowest total power consumption-10%b. Lowest gathered resources-5%

IV. Greatest availability of technology-15%V. Greatest reliability and with lowest maintenance-10%

VI. Lowest cost-10%

1.5 Testable Requirements Validate that the purification process should be treating and removing the contaminants,

Microorganisms > 0.5 microns and Viruses < 0.5 microns Check that the water purification filters should remove the taste, odor, organic

compounds and bacterium in order to verify the water is usable Test if the solar cooker can heat 6kg of water to 80 C⁰ in less than 4 hrs Validate that the power for the solar cooker is supplied by solar energy or biomass Test that the capacity of the shelter is quite sufficient for 10 people with all their gear. Validate that the renewable energy system will provide power with 110V/220V not less

than 1000 watts load. Check that the storage of batteries will last for 24hrs at least under full load. Communication system capable of linking to local cell phone networks and transmitting

text, voice and photos.

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2. Alternative Design Concepts2.1 Significant Features of the Alternative Designs In designing the PEAK system four major subsystems had to be considered: water purification, cooker and power generation. To help narrow design parameters the water purification system was fixed. Both a solar and wood cooker was considered. Power is generated either by solar panels or wind turbines. Design 2, 3, and 4 where not selected as the final design and will be discussed below. Design 1 was selected as the proposed system will be discussed in section 3 of this report

1. Design 2 Solar Cooker is used to prepare meals Wind energy system is used primarily to provide 3.5kW of power to the unit. Satellite Communication Systems.

2. Design 3 Wood Cooker is used to prepare meals No renewable energy resource related to solar was used Wind energy system primarily provides 2 kW power. Satellite Communication Systems.

3. Design 4 Solar Cooker is used primarily to produce meals Solar energy system is used primary source of power (2kW). Satellite Communication Systems.

Table 2: Design Configuration

Design Configurations

Component Design 1 Design 2 Design 3 Design 4

Water Purification Water Water Water Water

Cooker Solar Solar Wood Solar

CommunicationLocal and Satellite Access

Local and Satellite Access



Power Generation Solar- 1kW Wind- 6kW Wind- 2kW Solar- 2kW

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2.2 Overall Schematics of Subsystems and Components2.2.1 Design 2

Figure 1: Complete Design 2

2.2.1.1 Water PurifierWater Purifier Specification

Usability PortableOperated Power Source 110 or 220 V A.C. or 12 V D.C.

Total Power Consumption (Pump and UV) 24 Watts Rated Water Pressure 20 PSI minimum / 65 PSI maximum

Self Priming Water Pump Max. 1 gallon/min & 1.8 amps max per hour depending on head.

UV Lamp Output 30,000 μWs /cm2

UV Bulb – Life Expectancy 8000 hours, or Approx. 2 yearsSediment Filter (Pre-filter) 5.0 microns

Carbon Block Polishing Filter 0.5 micronsCarbon Block Polishing –

Filter Life Expectancy10,000 gallons or

1 year of clean incoming water maxCrystal Filter Phosphate

Water Treating Composition (Segment-A) Zeolite, Cupic Oxide (ARTI-64)Table 3.1: Water Purifier Specifications

The complete water purification system will have two segments Segment-A and Segment-B (see appendix 5.20)

Segment-A: The number/shape/material of sections comprising the column can vary. It will have two polyvinyl chloride (PVC) cylindrical sections. Water is poured through the top section and allowed to move, via gravity, downwardly through the lower section and out an outlet disposed in the lower portion which is connected to an inlet of Segment-B. The respective sections would be constructed of high-density plastic that will withstand a 15 mph drop [US 2006/0180550 A1].

Each section is designed to contain or hold a water treating composition. In the case of this embodiment, each section is provided with a pair of screens approximately 200 mesh and constructed of stainless steel (Fig. 1a: Segment-A item-28). Two different water treating

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compositions zeolite, cupic oxide (ARTI64) within two separate porous containers will be placed on two axially spaced apart screens from top to bottom section, respectively. Various types of porous containers can be utilized. They may include filter pillows or a porous container such as a tea bag structure. [US 2006/0180550 A1]

Segment-A is primary use to remove arsenics from the water. All functions of the Segment-A described in the following:

Zeolite: it can be housed or contained within one of the porous containers, and would function as a filtering media and would also function to partially remove ions. It is pellet form and approximately 150 mesh sizes, which would allow an adequate flow of water there through and provide sufficient contact time in a gravity flow situation for the removal of nitrogen based compounds as well. This size zeolite would also allow for the removal of suspended solids from the water.

Cupric oxide/ARTI-64: This water treating composition will remove arsenic as As3 and As5 from water.

Segment-B: Water flow through Segment-A to Segment-B to provide a purification system capable of decontaminating water making it suitable for human consumption which includes:

Preliminary filter that will remove sand, silt, sludge, and other particulate matter Polishing carbon filtration with pore size of 0.5 microns to remove taste, odor, organic

compounds and bacterium Phosphate crystal filter to remove calcium UV chamber to received 30,000 microwatt seconds per square centimeter of UV light

minimum which is a higher level of exposure that is needed to kill bacterium [Patent# 4,849,100]

2.2.1.2 Solar CookerIt was assumed that the average solar radiation in the horizontal plane was 450W/m2. This assumption was based on the total solar radiation that regions in Africa receive. A map and calculation of solar radiation can be found in the appendix of this report.

Efficiency of solar cooker is defined as energy needed to raise the temperature of water over the energy incident on the cooker (See appendix for complete definition) (Ozturk):

Similar cooker designs found in the literature reported efficiencies as high as 61% and as low as 20% (Funk 2000). A conservative estimate of 25% efficiency was assumed for the solar cooker. A cook time of four hours was assumed for the cooker. The increased radiation on the cooker from the reflector plates is calculated from a performance factor (See appendix for performance factor definition). A performance factor of one was assumed for the solar cooker.

A heating element will be used to cook food when solar energy is unavailable. A 650W electric heating element on the bottom of the cooker will provide heat. The heating element will be powered 120VAC drawing at a maximum 5.4A. The efficiency of the heating element was assumed to be 98%.

The pressure inside the solar cooker is assumed to be atmospheric pressure. The box is not air tight meaning air is free is escape. The temperature inside the cooker can be estimated around 120 C. Based on energy calculations it was found that 0.6m⁰ 2 of window area is needed. A square

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design of the solar cooker was considered with the length of each side equal to 0.8m. The window will sit at angle close to 45 with respect to the horizontal.⁰

Reflectors will also be square and made of polished 20 gauge stainless steel. Mounted on hinges the reflectors will be able to fold up for transportation. With the reflectors folded away the overall dimensions of the cooker are: 0.8m x .57m x .57m

Note: The more maintenance information and costs can be found in Table 33.

2.2.1.4 Wind Power System In order to produce 3.5 kW power generation uses 5000 W turbine from Liten Wind Power Co. Ltd with 20 SAFT Ni-Mh batteries (12V-100Ah), weighing 18.5 kg, for 8 hour backup power. A 5.5kW JP-8/Diesel Pramac Power Generator will be used to provide power in case of emergency. The hydraulic tower, controller, and inverter are same for this improved design as for the original design.

Liten LT6.5 5000 Wind TurbineRated Power 5000 WMax Power 6000 W

Output Voltage 220V-300VGenerator 3-phase, permanent magnet

Start-up Speed 2 m/sNumber of

Blades 3

Blade Material Reinforced fiber glass Rotor Diameter 6.4 m

Table 2.2: Liten 5kW Wind Turbine Specification

Saft NHE (Ni-MH) Battery (20 Pieces)Nominal Voltage (V) 12Rated capacity (Ah) 100

Specific Energy (Wh/Kg) 66Specific Power ( W/Kg) 150

Weight (kg) 18.5 (each)Table 2.3 – Saft NHE Battery Specification

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.2.2 Design 3


2.2.2.1 Water Purifier: Refer to Design 2

2.2.2.2 Wood OvenThe wood oven was quoted by the manufacture has having a efficiency of 75% (nectre.com). This efficiency is defined as the about of heat that leaves oven over the total energy input. Meaning, 25% of the energy is lost thought the smoke stack. It was estimated that actual cooking efficiency is 15%. Meaning, 15% of the input energy goes into heating the food. A heating element will be used to cook food when wood is unavailable. A 750W electric heating element on the bottom of the cooker will provide heat. The heating element will be powered 120VAC drawing at a maximum 6.3A. The efficiency of the heating element was assumed to be 98%. A steady state temperature of 150 C can be assumed for the lower cooking chamber. After the oven⁰ has reached steady state the following mass and volume flow rates can be estimated:

Wood Oven Mass & Flow RatesWood Mass Burn Rate 4.22 kg/hrAir Intake Mass Flow 0.04 kg/s

Air Intake Volume Flow 0.033 m3/sExhaust Mass Flow 0.042 kg/s

Exahust Volume Flow 0.047 m3/sTable 2.4: Wood stove mass and volume flow rates

From our assumptions in the loads, the total loads required is 2000 W. Sizing the turbine for this load, it was assumed that 6.53 m/s wind speed is present at 12m height with air density of 1.19 kg/m3. Using the power equation for wind turbine, it was determined that a wind turbine with swept area of 32 m2 and rotor diameter of 6.33 m, will be able to produce 2000W. (See Appendix 7.3 for further calculations). The selected wind turbine is a 5,000 kW model from Liten Wind Power Co. Ltd. with 6.40 m (about equal to calculated value) rotor diameter and three reinforced fiber glass blades, the turbine has start up speed of 2.0 m/s and rated speed of 10 m/s. It has a three-phase permanent magnet generator which runs at 220V-300V. The turbine gives an energy output of 3000W at 6.5m/s (Figure 2) with the tower a height of 12 m, which is more than

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sufficient for the required 2000W. (Refer to Section 2.2.1.4 for more Liten 5kW wind turbine specifications)

A hydraulic tower of 12m height was selected for this system. Hydraulic towers are easy to install and to be maintained as they use the hydraulic system to erect and lay down the wind-turbine generator. Therefore, there is no need of crane to install the tower saving installation and maintenance cost in long term.

A charge controller by Liten Wind Power rated for 5000 W power is chosen to regulate the voltage from wind generator to batteries. Liten Wind Power 5kW off-grid inverter generates a 5 kW output power and 220VAC/110VAC output voltage at 50Hz/60Hz. A battery bank of 20 SAFT Ni-Mh batteries, discharging at a depth of 50%, will be used to backup power for about 8 hours. The 20 batteries are connected in series. Each battery has a voltage of 12VDC, and nominal capacity ampere-hours of 100Ah. (Refer to Appendix Section 1.5 for Battery Sizing). 2,000W generator by Mechron Power system will be used in case the wind power system fails to produce the required power to support the house loads. The generator outputs a voltage of 120V/240V at 50Hz/60Hz with fuel oil tank capacity of 6.2 L.

2.2.3 Design 4


2.2.3.1 Water Purifier: Refer to Design 2

2.2.3.2 Solar Coker: Refer to Design 2

2.2.3.3 Solar Power- 2W: Refer to Design 3A solar-diesel power system consists of pv-array, charge controller, battery bank, and an inverter. In this design to produce 2kW, the PV-array of 17 panels of SHARP NU-U240F1 rated at 8.65 amps, and employs a battery bank of 28 Saft NHE-MH batteries (for 1 autonomous day) rated at 12v and 100Ah. The newly chosen Saft batteries weigh at 18.5 kg each. 2kw JP-8 backup generator is same as Design 3.

Note: Refer to Section 2.2.2.4 for specifications on batteries. Refer to Section 3.1 solar panel specifications.

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2.3 Energy and Environmental Analyses 2.3.1 Design 2

2.3.1.1 Water Purifier Water purifier is environmental affable, built-in flexibility, and easy to operate devices. In this design, PVC pipe (most commonly used in water systems) is used which does not rust, rot, or wear over time. PVC Plastic and stainless steel that are used in this design are durable, hard to damage, long lasting and recyclable. Arsenic consumption leads to higher rates of some cancers, including tumors of the lung, bladder and skin, and other lung conditions [BBC News]. So, it is very important to remove arsenics from drinking water. Segment-A is added to this water purifier to remove arsenics from the drinking water.

2.3.1.2 Solar CookerSolar cookers are environmentally friendly devices. They emit no CO2 or any other harmful emissions. The cooker is reusable for many years. At the end of its life cycle the majority of the materials including glass and steel can be recycled.

2.3.1.3 Wind Power GenerationThe wind power system uses the cleanest renewable resource wind, as it neither emits any greenhouse gases nor other pollutants such as SO2 or NOx. The bird kill due to wind power system is the only major environmental impact. The 5kW generator is rated at 70 dBA sound level at 7m, which is considered as the sound level of washing machine, which indicates that it is less likely to harmful in a long running time. The generator meets EPA Tier 2 indicating that states it emits about 6.6 g/kWh of CO2 and 7.5 g/kWh of Non-Mehtane Hydrocarbon Compounds & NOx in the environment. Environmental consideration of Design-1 of solar generation is valid for wind generation.

2.3.2 Design 3

2.3.2.1 Water Purifier - Refer to 2.3.1.1

2.3.2.2 Wood CookerWood is a carbon based fuel and releases CO2 when it burns. CO2 is a green house gas and has been linked to global warming. Other significant combustion products include nitrogen oxide, benzo(a)pyrene, napthalene, arthracene, phenanthrene, biphenyl, fluoranthene, pyrene, chrysene, benzene, pyrelene, dioxin and heavy metals (maine.gov).

2.3.2.3 Wind Generation Refer to 2.3.1.4

2.3.3 Design 4

2.3.3.1 Water Purifier: Refer to 2.3.1.1

2.3.3.2 Solar Cooker: Refer to 2.3.1.2

2.4.3.3 Solar GenerationSolar/wind electric systems or photovoltaic (PV) have little environmental impact, making them one of the cleanest energy technologies available today. While operating, PV systems produce no

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air pollution, noise pollution, greenhouse gas emissions, or hazardous waste. Investing in a PV system allows one to play an active role in mitigating environmental problems such as global warming, air pollution, and the devastating effects of strip mining. The electric generation have lead-acid batteries are the environmental success story of our time. Roughly 96 percent of all battery lead is recycled. Compared to newspapers, aluminum cans and glass bottles, lead-acid batteries top the list of the most highly recycled consumer product. The lead-acid battery gains its environmental edge from its closed-loop life cycle. The typical new lead-acid battery contains 60 to 80 percent recycled lead and plastic. When a spent battery is collected, it is sent to a permitted recycler where, under strict environmental regulations, the lead and plastic are reclaimed and sent to a new battery manufacturer. The recycling cycle goes on indefinitely. That means the lead and plastic in the lead-acid battery in your car, truck, boat or motorcycle have been - and will continue to be recycled many, many times.

2.4 Packaging Breakdown 2.4.1 Design 2

For this specific design, the solar cooker and water purification can be installed by one to two people with ease. The tents and its gear can be established by four to five people. The crucial issue would be the deployment of the wind-diesel power system. Firstly, the wind-generator and blades can be connected to the yaw shaft by 4 people using the provided toolbox. For the wind power system, firstly the hydraulic tower will be needed to set up by 2 people at least. An electric hydraulic system, to help erect the tower, would be delivered by the manufacturer. The 20 batteries, each weighing 18.5 kg, can be set up by 2 people. A toolbox will be provided with all the tools needed to install wind turbine power system. A large dolly would be made available in order to move heavy wind-turbine parts.

Design 2 Volume Information

Component Calculation Volume (m3)

Water PurifierSegment A) V= πr2h = π*(6in)2*18in=2035.75 in3=0.03 m3

Segment B) V=22in*18in*10in=3960 in3 = 0.06489 m30.98530

Solar Cooker 0.8m x .8m x .25m 0.160

3.5 kW Wind-Diesel Power System

Volume (m3)Wind Turbine +

BladesGenerator 0.286

4.8301777

Blades 0.456

Hydraulic Tower (12m)

Upper Section 0.008Middle Section 0.0154

Bottom Section 3.405

Inverter 0.0936Controller 1.78E-04

Battery 0.186Fossil fuel Generator 0.380

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TOTAL 6.12Table 2.5– Design 2 Volume Information

2.4.2 Design 3For this design, water purification can be installed by person without difficulty. It would take at least 2 people to install the wood cover. The tents and its gear can be established by four to five people. The challenge will come with the deployment of the wind-diesel power system and absorption system. Firstly, the wind-generator and blades will be attached to yaw shaft by 3 people using the provided toolbox. For the wind power system, firstly the hydraulic tower will be needed to set up by 2 people at least. An electric hydraulic system, to help erect the tower, would be delivered by the manufacturer. The 20 batteries, each weighing 18.5 kg, can be set up by 2 people. The absorption system set up, weighting about 1300 kg, can be put up by at least 5 people. A large dolly would be provided to move heavy equipment. A toolbox will be provided with all the tools needed to install wind turbine power system and absorption system.



Water PurifierSegment A) V= πr2h = π*(6in)2*18in=2035.75 in3=0.03 m3

Segment B) V=22in*18in*10in=3960 in3 = 0.06489 m30.99

Wood Cooker 0.0.83m x 0.54m x 0.54m =0.242028 m3 0.242

2 kW Wind-Diesel Power System Combined Components = 4.83 m3 4.83

Absorption System & SmallTent

Chilli PSC12: 0.8m x 0.6m x 2.2m=1.056, cooling tower: 0.8m x 0.6m x 2.0m=0.96, controler: 0.3m x 0.12m x 0.3m=0.0108, Boiler: 1.17m x 0.610m x 1.58m=1.12765, and Tent: 0.79m3

4.10

TOTAL 10.16Table 2.6– Design 3 Volume Information

2.4.3 Design 4Solar cooker and water purification can be set up easily by one to two people. Four to five people can erect the tent using the tools from a standard toolbox. The one of the major part in the installation is the deployment of solar panels and batteries for the solar-diesel power system. There are 17 solar panels, each weighting 20 kg, are required to build the PV array. At least 2 people are needed to put up the panels on the mount racks. The 4 batteries, each weighing 18.5 kg, can be set up by 2 people. The key task would be installation of the absorption system, weighing about 1300kg. With having a HVAC unit, absorption chiller, and boiler in the absorption system, at least 5 people would be needed to deploy the system. Wood cutting and splitting tools will be made available for the wood needed for the boiler. A toolbox with all the tools needed to set up the battery and solar panels will be made available by the manufacturer. Also, a dolly would be provided in order to transport the heavy batteries.

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Water Purifier Segment A) V= πr2h = π*(6in)2*18in=2035.75 in3 = 0.03 m3

Segment B) V=22in*18in*10in=3960 in3 = 0.06489 ^3 0.99

Solar Cooker 0.8m x .57m x .57m = 0.25992m3 0.26

Solar-Diesel Power System

Size Each (m) Volume Total (m3)

1.75PV panel (SHARP NU-

U240F1) 1.64* 0.958*0.046 1.22861584

Battery (SAFT NHE-MH 12v 100Ah) 0.390* 0.195* 0.120 0.255528

2kW Pramac Generator 0.169Absorption

System & Small Tent

Chilli PSC12: 0.8m x 0.6m x 2.2m=1.056, cooling tower: 0.8m x 0.6m x 2.0m=0.96, controler: 0.3m x 0.12m x 0.3m=0.0108, Boiler: 1.17m x

0.610m x 1.58m=1.12765, and Tent: 0.79m34.10

TOTAL 7.10Table 2.7 – Design 4 Volume Information

Component

Design 2 Design 3 Design 4 Weight

(kg)Weight (lbs.)

Weight (kg)

Weight (lbs.)

Weight (kg)

Weight (lbs.)

Water Purifier 24.95 55.01 24.95 55.01 24.95 55.01Wood Cooker 62.87 138.62 124.74 275.05 124.74 275.05

Wind-Diesel Power System 2404.50 5301.92 2348.50 5178.44 948.70 2091.88TOTAL 2508.42 5333.56 2465.22 5463.81 1265.42 2377.25

Table 2.8: Alternative Designs Total Weight

2.5 Economic Analyses2.5.1 Initial Purchase Cost

Design 2 Design 3 Design 4 Component Cost (USD) Cost (USD) Cost (USD)

Water Purifier $2,165.00 $2,165.00 $2,165.00

Solar Cooker $870.00 $2,540.00 $2,540.00Wind-Diesel Power

System $37,999.00 $34,498.00 $29,482.78

Total $41,527.92 $49,722.25 $38,707.03Table 2.9: Alternative Designs Initial Purchase Cost

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2.5.2 Annual Maintenance Cost

Design 2 Design 3 Design 4 Component Cost (USD) Cost (USD) Cost (USD)

Water Purifier $410.00 $410.00 $410.00Solar Cooker $50.00 $150.00 $50.00

3.5 kW Wind-Diesel Power System $2900.00 $2620.00 $1420.00

Total $3176.00 $3216.00 $716.00Table 2.10: Alternative Designs Annual Maintenance Cost

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3. Decision Making & Presentation of the Proposed System

3.1 Technical Analysis The design uses solar energy for both the cooker and power generation. The HVAC is a conventional unit that both cools and heats the shelter. The solar panels are used as a primary source of power and are backed up by a diesel generator. (Refer to Appendix V for further information)

3.1.1 Water Purifier

Figure 3.1: Aqua Sun International Responder A

Water Purifier SpecificationUsability Portable

Operated Power Source 110 or 220 V A.C. or 12 V D.C.Total Power Consumption (Pump and UV) 24 Watts

Rated Water Pressure 20 PSI minimum / 65 PSI maximum

Self Priming Water Pump Max. 1 gallon/min & 1.8 amps max per hour depending on head.

UV Lamp Output 30,000 μWs /cm2

UV Bulb – Life Expectancy 8000 hours, or Approx. 2 yearsSediment Filter (Pre-filter) 5.0 microns

Sediment Filter - Life Expectancy Depends on how dirty incoming water is or1 year maximum

Carbon Block Polishing Filter 0.5 micronsCarbon Block Polishing –

Filter Life Expectancy10,000 gallons or

1 year of clean incoming water maxCrystal Filter Phosphate

Water Treating Composition (Segment-A) Zeolite, Cupic Oxide (ARTI-64)Table 3.1: Water Purifier Specifications

19

3.1.2 Solar Cooker

Figure 3.2: Solar Cooker

Solar Cooker SpecificationsWidow size L x W (m) 0.8 x 0.8Window transmissivity 83%

Overall Dimensions L x W x H0.8 x 0.8 x

0.25Maximum cooker air Temperature (⁰C) 128

Maximum interior surface temperature (⁰C) 128Reflector Size L x W (m) 0.8 x 0.8

Reflector number 4Reflector angles (w.r.t ground) 45⁰

Reflector Material SteelTable 3.2 – Solar Cooker Specifications

3.1.3 Communication

Figure 3.3: NGC Deployable Digital System

20

Manufacture Lockheed MartinModel MCS

Voltage 220/110Current (amp) 0.9

Power Consumption (W) 160Cost $8,005.00

Table 4.3: HVAC unit Specifications

3.1.4 Solar Power System

Figure 3.4: Solar Power System

Zytec– LCPV Panels (3 Pieces)Maximum power (Pmax) 240 [W]

Type of Cell Monocrystalline siliconPower Voltage (Vpm) 30.1 [V]

Maximum Power Current (Ipm) 6.55 AMaximum System (DC) Voltage 600 V

Weight 20 kg (each)Table 3.4 – Sharp PV Panel Specification

Saft NHE (Ni-MH) Battery (10 Pieces)Nominal Voltage (V) 12Rated capacity (Ah) 100

Specific Energy (Wh/Kg) 66Specific Power ( W/Kg) 150

Weight (kg) 18.5 (each)Table 3.5 – Saft NHE Battery Specification

21

3.2 Decision Making AnalysisThroughout the design process of the Pre-positioned Expeditionary Assistance Kits (PEAKs), there were specifications, constraints, and criteria that were developed and modified. During the designing process, there were four different designs that were constructed to be evaluated. Two different decision matrixes processes were used. The first decision matrix (Table 3.6) (yes/no entries) was applied on all four designs to find out whether or not each design met the demands on the specifications and constraints. The second decision matrix is called Pugh Analysis, which number entries were applied on all designs using criteria as categories. The weighting percentage was assign a numerical value to each category of criteria was used to justify decision making process.

Overall Specifications/Constraints for All PEAK Systems Design

Location East Africa 1 2 3 4Overall Power Generation Must be renewable and fossil fuel sources of energy and must meet EPA Standards

EU emissions standards.Y Y Y Y

Electricity 110V / 220V and 60 Hz Y Y Y Y

Power Consumption

Design 1 & 2: Less Than 6 kW; Design

3 & 4: Less Than 2kW

Y Y Y Y

Total Weight Less than 5,000 lbs Y Y Y YPackaging / Volume Fits on a 463L Pallet Y Y Y Y

SafetyAll components meet

safe operation standards

Y Y Y Y

Power Source Electrical, Battery or Wasted Heat Y Y Y Y

Water Purifier

Filtered contaminants

Microorganisms > 0.5 microns; Viruses

< 0.5 micronsY Y Y Y

Polishing Carbon Filtration Y Y Y Y

RemoveTaste, Odor, Organic

compounds and bacterium

Y Y Y Y

Power Source Electrical Y Y Y YWater Supply 370 L water per day Y Y Y YCooker Power Supply Sun or Biomass Y Y Y YSecondary Power Supply

Electrical Heating Coils Y Y Y Y

Heating Capacity6 kg of water to

100oC in less than 4 hrs

Y Y Y Y

Table 3.6: Decision Matrix on Specification/Constraints

22

The baseline/datum in this Pugh analysis is Design 1, which is the design in which all others are compared. Design 1 is thought to be the most effective out of all the Pre-positioned Expeditionary Assistance Kits. The kit that makes up design 1 is the fixed water purifier, solar cooker and Solar power generation. Once the evaluation was performed for all the points, each point weighted total was multiplied by the score compared to baseline/datum. If the score was a positive, equal/same or negative then “+”, “S”, or “-” was entered, respectively. The multiplied value is called the evaluated total, and then the evaluated totals are all summed to give the weighted totals compared to the datum design. From the evaluation, it is determined that the datum design meets all the needs of the design group’s emphasis. (Refer to Appendix 8 for further information)

Weight (%) Design1 Design2 Design3 Design4Smallest size 10 D - - SLowest weight 15 A - - -Best durability for environment 10 T - - SLowest environmental Impact 10 U S - -Lowest total power consumption 10 M S + +Lowest JP8 consumption 5 S - + Lowest gathered resources 5 S - -

15 S S -10 - - S10 + + +

Total + 0 1 2 3Total - 0 4 7 4

Overall total 0 -3 -5 -1Weighted total 0 -35 -45 -20

Lowest cost

Environmental Consideration:

Consumption Effi ciency:

AlternativesRequirements

Best packaging & transportability:

Greatest Availability of technology Greatest reliability and with lowest maintenance

Table 3.7: Pugh Analysis

3.3 Final Design: Overall Schematics of Subsystems and ComponentsDesign 1 (see below figure) was confirmed by the Pugh analysis (Table 3.7) to be the best design, with the descending order being Design 4, Design 2, and Design 3. The total volume for this design approximately is 2.652 m3.

Figure 3.5: Complete Design 1

3.4 Mass and Energy Flow of Subsystems and ComponentsIn order to better understand how energy would be consumed during a typical day an energy analyses was completed on the entire system. Two different scenarios where consider: a day with

23

Water Purifier

11 LCPV Panels

Charge Controller

Inverter

Solar Cooker

HVAC

Distribution Board

18 NHE Batteries

Solar Cooker

Shelter

full sunlight and a day with no usable energy. Two plots were generated for both cases. The first plot shows power consumption and generation though out a 24-hour day. The second plot shows the battery energy level thought out the day. The first case considered below shows a typical day with no clouds.

Figure 3.6: Sunny day: power consumption and generation

Figure 3.7: Sunny day: battery energy

On a clear day solar radiation will both produce energy and cook food in the solar cooker. No energy needs to be supplied to the solar cooker under good solar conditions. The water purifier consumes a small amount of power when compared to the entire system 1kW of extra power has

24

been allotted during day time hours for communication and other equipment. The following two plots show a typical day’s power consumption when no solar energy is available.

Figure 3.8: Cloudy day: power consumption and generation

Figure 3.9: Cloudy day: battery energy

The figures above show that the generator must be run 24 hours a day to power the necessary loads. The water purifier and miscellaneous loads are the same as the sunny day case. Without solar energy the solar cooker must be supplied with 1kW of power. The battery has no usable

25

energy when no solar energy is available. The battery can only be charged by the DC loads of the solar panels.

3.5 Packaging and InstallationThe completed kit and consumables will fit on a single 463L Cargo Air Pallet for air deployment with usable space of 84 in x 104 in x 104 in. The total weight of the system is 3689lb which is less than the maximum allowance weight for the Cargo Air Pallet (10,000 lbs). For land deployment, the package could be towed by HMMWV vehicle or HEMTT A4 w. LTAS-B military truck. The kit must be setup and working in 8 hour’s time. All parts of the kit will be able to withstand climate similar to East Africa with temperatures ranging from 20 - 105⁰F. All the equipment will be packaged in individual boxes with a fragile warning for a safe packing and deploying. The heaviest equipment is set directly on the pallet; the water purifier and solar cooker are light so they can be placed on top.

Figure 3.10: Packaging Configuration

The installation of this design is simple and easy. Solar cooker and water purification can be set up easily by one to two people. The major part in the installation is the deployment of solar panels and batteries. There are 3 solar panels, each weighting 20 kg, are required to build the PV array. At least 2 people are needed to put up the panels on the mount racks. The 10 batteries, each weighing 18.5 kg, can be set up by 2 people. A toolbox with all the tools needed to set up the battery and solar panels will be made available by the manufacturer. Also, a dolly would be provided in order to transport the heavy batteries.

26

84in

92in

104in



Water Purifier Segment A) V= πr2h = π*(6in)2*18in=2035.75 in3 = 0.03 m3 Segment B) V=22in*18in*10in=3960 in3 = 0.06489 ^3 0.99

Solar Cooker 0.8m x .8m x .25m = 0.25992m3 0.16

1 kW Solar-Diesel Power

System

Size Each (m) Volume Total (m3)

0.793 LCPV panel 1.64* 0.958*0.046 0.63610 Battery (SAFT NHE-

MH 12v 100Ah)0.390* 0.195*

0.120 0.164

TOTAL 2.562Table 3.8: Final Design Volume Information

Final Design Component Weight (kg) Weight (lbs.)Water Purifier 24.95 55.01Solar Cooker 62.87 138.62Solar Power System 245 539TOTAL 332 732.8

Table 3.9: Final Design Total Weight

27

3.6 Materials and Economic Analysis3.6.1 Initial Purchase Cost

Design 1Component Cost (USD) VendorWater Purifier $2,165.00 Aqua Sun International

Solar Cooker $870.00 Sun-Ovens InternationalSolar-Diesel Power System $18000.50 Zytec LCPV /Saft InternationalNGC Communication System $16,005.00

Lockheed Martin

Total $37,040.50Table 3.10: Final Design Initial Purchase Cost

3.6.2 Annual Maintenance CostAnnual Maintenance Cost

Component Cost (USD)/YrWater Purifier $410.00Solar Cooker $50.001 kW Solar Power System $2500.00Communication System $216.00Total $3176.00

Table 3.11: Final Design Maintenance Cost

3.7 Safety Analysis of the Final DesignThis section focuses on the safety of the components individually and as a system. The design that is analyzed for safety in this section is design one, which was carefully selected using Pugh analysis. The FMEA (Failure Mode and Effect Analysis) method is used for conducting the safety analysis.

3.7.1 Water PurifierThe water purifier has few potential failure modes such as Ultraviolet (UV) light is off, bad tasting water or water is dirty, flow is slow, and/or no water flow at all. If it isn’t treated properly, those harmful elements can cause serious health issues for human beings. It is very important to read the water purifier manual/instruction before it can be used. In addition, users should understand potential failure modes, effects of failure, causes of failure, and what actions need to take in order to fix the problem and get the safe drinking water. This water purifier has UV light that indicates water is safe to drink or not. Clean, safe and natural UV light rays have the ability to kill the bacteria and virus to 99.999 % purity without any harmful side effects much like chemical agents normally added to drinking water. User should also know approximate filter life expectancy.

28

3.7.2 Solar CookerThe function of the solar cooker is to cook food to the proper temperature. Two potential failure modes for the solar cooker exist: undercooked food and overcooked food. In both failure modes the quality of the food is affected. Undercooked food presents a far greater risk than overcooked food. Undercooked meats can contain harmful bacteria and other parasites. While overcooking food does not present a health risk the quality of the food can be degraded. When food is overcooked it can become less nutritious and less desirable. Food may serve to boost morale of relief works. A lower quality food may cause a lower productivity.

Four failure modes were evaluated that could lead to undercooked food. Failure in the heating coil or temperature controller may lead to a lower cooking temperature. Under ideal solar conditions food would still be cooked. The chance of either one of these components failing is relatively small. A dirty window was identified as a third failure mode. A clean window is necessary to allow solar radiation must pass though the window. Lack of both solar and electrical power was identified as a fourth failure mode.

Two additional causes of failure were identified for over cooked food. Again, if the temperature controller fails the temperature inside the oven could rise steeply. At higher temperatures food would be cooked more quickly. Like any conventional oven, if food is left in the cooker for too long the food will become overcooked. This risk is reduced by use of a timer.

Based on different failure modes discovered two design improvement will be implemented. First, a thermocouple feedback system will be added to ensure food is cooked to the proper temperature. A thermocouple will be inserted into the uncooked food. The temperature will be measured and compared to a preset threshold. When the threshold is met an indicator will turn on. Second, a window cleaning kit will be included to ensure the window is kept clean. A clean window will allow more solar radiation to pass into the oven.

29

# FunctionPotential Failure Modes

Potential Effects of

Failure

SEV

Clas

sPotential

Causes of Failure

OCC

Current Design

Controls

DET

RPN

Recommend Actions

Responsible Person & Target

Date

Actions Taken

SEV

OCC

DET

RPN

1 UV light UV light is not on

Stop water flow 9 No power 6 None 1 54

Supply Aux 12 V

electrical power

Jahirul Chowdhury

Purifier wouldn"t work until

isupply Aux 12 V

electric power

1 1 1 1

2 Stop water flow 9

UV bulb reached unsafe

condition

3 None 1 27 Install new UV bulbs

Jahirul Chowdhury

Purifier wouldn"t work until install new UV bulbs

1 1 1 1

3 Purified water

Water is dirty or bad tasting

waterFilter problems 8

Filter reached maximum life expectancy

3 None 5 120 Replace all the filters

Jahirul Chowdhury

Don"t use it until

reaplce all the filters

2 3 1 6

4 Water flow is slow

Washable/ Reusable Pre-

Filter is wedged

3 Dirty incoming water 2 None 1 6 Wash/clean

the pre-filter Jahirul

Chowdhury

For faster flow,

washing pre-fliter is required

1 1 1 1

Table 3.12: Water Purification DMFEA

# Function Potential Failure Modes

Potential Effects of

Failure

SEV

Clas

s Potential Causes of Failure

OCC

Current Design

Controls

DET

RPN

Recommend ActionsResponsible

Person & Target Date

Actions TakenSEV

OCC

DET

RPN

1 Cook Food Undercooked Food Unsafe Food 3 Heating Coil Fails 5 None 5 75 Add Thermocouple

Feedback E. Gingrich Added Thermocouple Feedback 3 5 3 45

2 4 Temperature Controler Fails 5 None 5 100 Add Thermocouple

Feedback E. Gingrich Added Thermocouple Feedback 4 5 3 60

3 5 Dirty Window 10 None 5 250 Clean window E. Gingrich Incluced Cleaning Kit 5 10 1 50

4 9 Not enough Solar or electrical Energy 6 None 5 270 See power generation

FMEA

5 ##

6 Over-done Food

Bad tasting food 4 Temperature

Controler Fails 5 None 5 100 Add Thermocouple Feedback E. Gingrich Added Thermocouple

Feedback 4 5 3 60

7 4 Long cooking time 4 Food Timmer 2 32 None 4 4 2 32

Table 3.13: Solar Cooker DMFEA

3.7.3 Power Generation: Solar Power and Backup Generator

3.7.3.1 Solar Power System DMFEA

Limited Sunlight: A solar cell is a solid state device that converts the energy of sunlight directly into electricity by the photovoltaic effect. A cloudy day provides sufficient diffuse light by which the panel will produce electricity. Optimum electrical production occurs with bright and sunny weather conditions. Under a light overcast, the modules might produce about half as much as under full sun, ranging down to as little as five to ten percent under a dark overcast day. In this particular system, the unavailability of the sunlight for 8 hours will lead the users to run the backup generator in order to keep the power for utilities.

Panel failure: Solar panels primarily manufactured of fragile materials such as glass and silicon, therefore, it is highly exposed to fracture or cracking whether during the installation or transportation. Any broken cell will affect on the amount power generated by the solar system. Need to check and follow the operation & maintenance instructions.

Controller Failure: The main purpose of the controller is regulating the flow of power from a solar panel into a rechargeable battery. Controllers can have a variety of output devices. Whether LEDs, digital displays, audible sounds or others; they can easily tell the users the status of the PV system. Controllers are sized according to maximum array charging current. Any damage in this device will lead to a higher potential of the batteries becoming damaged by overcharge, excessive discharge, or both. Need to check and follow the operation & maintenance instructions.

Inverter Failure: In a solar power system the Inverter changes the DC power generated by the solar panels to AC power that is used in the facilities. Inverter size and installation location are the most important considerations especially in hot climates. Most Inverters are rated for a maximum ambient temperature of 105 degrees F. Designers and installers with extensive local knowledge know that by slightly over-sizing the Inverter (10-20%), it will run cooler, last longer, and experience fewer problems. Any serious issue with the inverter will stop the entire power system. Need to check and follow the operation & maintenance instructions.

Battery Failure: Many reasons involved in the battery failure, basically it depends of the type of the battery. The Lead-Acid battery is the type most used in solar power systems because, while it

30

http://en.wikipedia.org/wiki/Photovoltaic_effect

http://en.wikipedia.org/wiki/Electricity

http://en.wikipedia.org/wiki/Solid_state

is the oldest (100+ years), it is also the cheapest and most reliable for the purpose of saving solar-generated electricity. Lead sulfate has built up on the plates inside the battery. In 80% of all cases of lead-acid battery failures, this is the cause. You have run them down too low too frequently. When the batteries fail, this means no ability to store energy to use through the assigned time. Need to check and follow the operation & maintenance instructions.

Wiring Failure: The amount of power a wire can safely carry is related to how hot it can safely get. Wires have resistance and as power flows through them, that resistance causes heat to build up. Insulation breaks down when it gets too hot, and at some point it will melt away; leaving the wire exposed to whatever is around it – possibly causing a fire. Also the poor quality work in installation and connection will damage the wires because of the power loose during the system operation. Corrosion is one of the reasons too and need to be considered while the normal checking for the system’s wiring. Need to check and follow the operation & maintenance instructions.

# FunctionPotential Failure Modes

Potential Effects of Failure

SEV

Clas

sPotential

Causes of Failure

OCC

Current Design ControlsDET

RPN

Recommend Actions

Responsible Person &

Target Date

Actions Taken

SEV

OCC

DET

RPN

1 Solar Power Generation

Limited Sunlight Failed to generate the

required power

3 Dust storm or cloudy days 4 Clean the panles. Operation &

Maintenance instructions 1 12

Clean the panles and Operation and

Maintenance instructions

Waleed Al-Taie, Era Raizada

3 4 1 12

2 Panel failedFailed to generate the

required power

8Piece broke

during installation or transporting

2 Operation & Maintenance instructions 3 48

Operation and Maintenance instructions


8 2 3 48

3 Conroller Failed

Failed to regulates the voltage & current

coming from panels to the battery

9 Device malfunction 3 Light detector. Operation &


Light detector and Operation and Maintenance instructions


9 3 1 27

4 Inverter FailedFailed to changes DC

voltage to AC from batteries or panels

9 Device malfunction 3 Light detector. Operation &




9 3 1 27

5 Battrey FailureFailed to obtain the

required power 9 Cells disqualification 3 Light detector. Operation &




9 3 1 27

6 Wiring Failure Failed to run the system 9 Corrosion 3

Check periodically the electrical connections for loose connections and corrosion. Operation &

Maintenance instructions

1 27

Check periodically the electrical

connections for loose connections

and corrosion.


9 3 1 27

Table 54: Solar Power System DMFEA

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3.8 Features & OperationsThis water purifier has two sections. First section is custom design and second section is Aqua Sun manufactures the Responder A Portable, 12-volt Powered Water Purification Systems for Remote Applications. This system has the capabilities of producing cleaner and safer drinking water from almost any creek, stream, pond, well, lake or most any fresh water source at a volume production rate of 1 gallon (3.7 liters) per minute where water purification and electrical power are impractical or unattainable. For continuous water purification production a 15 ft long 12-volt electrical power cord is provided with a cigarette lighter plug and battery jumper cable clips that can be plugged into any car, truck, boat, plane, generator or any 12-volt electrical power supply source. This system requires a 12 volt electrical power source, but there is no need for chemical additives.

The reflectors of the solar panel will be situated at 45 degrees with respect to the ground. The orientation of the cooker with respect to north does not matter. The cooker will be fitted with an electric heating coil that will add heat to the system when solar energy is unavailable. The heating element will be controlled by a temperature controller. The cooker should be setup in an area where it is free from shade.

Solar PV system converts the sunlight into useful electric energy while relying on battery backup during autonomous days and night. Battery Bank and PV arrays work together to provide the required amount of power. The system designed with various components that are selected according to system type, and site location. Off-grid PV system components include PV array, solar charge controller, inverter, battery, and fossil-fuel generator back-up. A solar panel consists of number of PV module, which is environmentally sealed group of PV Cells. Total 3 Zytec Low Concentration Photovoltaic Cells are the essential mechanism of the PV power system that converts the sunlight into electricity for this design.

Solar charge controller performs the task of maintain the charging voltage across the batteries. When solar cells produce more voltage due to intense daylight, the batteries can be damaged due to excessive voltage. Outback Flexmax 60 controller regulates the voltage for the system. It is rated at 12~60 VDC for 60A. As the system voltage is 24VDC, Outback Flexmax will adequately work for the system.Inverter is a tool that converts a DC voltage to AC voltage. It is essential for the PV system as the energy from PV array is stored in low voltage DC batteries. Univ-5000P off-grid inverter generates a 1000 kW MAX output power and 110/220 VAC output voltage. The inverter has the system voltage as its input voltage of 24VDC.

A battery bank is used to is store energy in the batteries for certain amount of days in order to have available power when there is little sunlight such as on cloudy days or during nighttime. Total 10 SAFT NHE 10-100 12 V, 100 Ah, discharging at a depth of 50%, will be used to backup power for about 24 hours. The 5 batteries are connected in parallel while the 2 batteries are in series. Each SAFT NHE Battery has a voltage of 12VDC, and nominal capacity ampere-hours of 100Ah.

32

4. Design Analysis & Verification4.1 Photovoltaic Power System / Backup Generator Design AnalysisA photovoltaic (PV) power system transforms the energy from the sunlight into electric current. Solar PV system is designed with various components that are selected according to system type, and site location. Off-grid PV system main components include PV arrays and batteries plus fossil-fuel generator back-up.

The system converts the sunlight into useful electric energy while relying on battery backup during autonomous days and night. Battery Bank and PV arrays work together to provide the required amount of power. In order to size the battery bank and arrays, the total load was configured to give Watts-Hour/Week.

Subsequently, Amp-Hours/day was calculated using 24VDC system voltage and weekly power demand.

Array Sizing

To determine the number of module, the storage (Ah)/day was recalculated with battery charge/discharge compensating factor. Then, Solar Array Amp was computed

Total Solar Array Amp= Ah/dayAverage Sun Hours

Amount of modules needed take into account solar array amp and optimum amp of solar module used.

Total Number of Module Required= Total Solar Array AmpsOptium Ampof Solar ModuleUsed .

Battery Sizing

The amount of storage (Ah) needed in maximum of cloudy days are determined.

Er=E × D

Then, the storage needed by the 50% depth of discharge is calculated

E safe=Er

0.5

Next , the capacity, C, of battery bank needed is evaluated while taking average wintertime ambient temperature in account. The battery bank consists of batteries that are either wired in series or parallel due to system requirements. The total number of batteries obtained.

N batteries=Capacity of the ba tterybank

capacity of onebattery

Refer to appendix III & V for design power system technical specifications.

33

4.2 Solar Cooker Design AnalysisThe design of the solar cooker can be best explained with a list of the steps that were used. The following steps are an overview of the design process of the solar cooker.

1. Establish design criteria that included heating 6kg of water to 100⁰C2. Perform a literature review of solar cooker designs3. Assume a cooker efficiency based on literature review4. Select a location on earth and calculate the average daytime irradiation5. Using the specific heat of water, assuming a cook time and coefficient of performance

(see appendix for definition) the intercept area can be calculated.6. Different designs can be evaluated using computational fluid dynamic software with solar

loading models.

The table below shows the assumptions made for the final solar cooker design.

Solar Cooker CalculationsPerformance factor 1Cook Time (hour) 4Water mass (g) 6000Density of water (kg/m3) 1000Heat Capacity Water (J/kg-K)

4186

∆T (K) 75Energy Needed (J) 188370

0Irradiation Needed (W) 131Area Needed (m2) 0.581

Figure 4.1: Solar cooker calculations

4.6 Solar Cooker VerificationIn order to verify the design of the solar cooker, a model of the cooker had to be drawn and then analyzed. The model of the tent was drawn using Gambit and Unigraphics NX5 software. The drawing was made into a mesh and imported to the Fluent program to be analyzed. The figure below shows an isometric view of the solar cooker.

34

Figure 4.1: Solar cooker, isometric view

In order to find the most efficient design two different variations were considered. Both designs had the same shape and dimensions. The first design was coved by a transparent glass window and in the second design the glass was removed.

4.4.1 Model ConditionsThe solar ray tracing model in Fluent was utilized to analyze the solar cooker. The solar calculator built into solar model allows the user to adjust for a particular place by inputting longitude and latitude coordinates. A location in East Africa with coordinates of 0 longitude, 38.5 latitude and 3 for time zone, was selected for design verification. Under the Model menu energy was turned on, standard wall function for viscous, and solar loading for radiation were selected. The day of the year was also inputted into the model. The values of June 21 at 12 pm were inputted into Fluent.

4.4.2 Material PropertiesThe solar cooker was modeled using three types of materials wood, glass and steel. The reflectors were made of steel, the side of the box out of wood, the and the window out of glass. The glass was modeled has having a transmissivity of 83% and an absorptivity of 9%. The physical and thermal properties of the materials can be seen in the table below.

Density

Specific Heat

Thermal Conductivity

kg/m3 j/kg-k w/m-kWood 700 2310 2310Steel 8030 502.48 16.27Glass 2220 830 1.15

Table 4.2: Solar cooker material properties

35

4.4.3 Boundary ConditionsThe inside of the cooker was modeled as air with not inlets or outlet. The entire cooker including the air was initialized to 22⁰C. The plane connecting the top of the reflectors was modeled as a pressure outlet.

4.4.4 CalculationsAfter the design parameters were entered, calculations could be performed with a total number of iterations set to 1,000. Both steady state and transient simulation where calculated. Only steady state results are reported below. The system did converge and the data was recorded. Some images can be seen of the results of the Fluent model.

Below a comparison can be made between the design with a glass over and the open design.

Figure 4.2: Cooker wall, contours of static temperature (degrees C), Left- With Glass, Right- Open

Figure 4.3: Cooker air, contours of static temperature (degrees C), Left- With Glass, Right- Open

36

Figure 4.4: Cooker air, velocity vectors colored by velocity magnitude (m/s), Left- With Glass, Right- Open

From the figures above it can be seen that using a solar cooker with a transparent piece of glass increases the temperature of the oven. With a glass cover the oven less heat is lost due to convection. The figure of velocity show a much smaller velocity field in the glass coved cooker. Both a higher air and surface temperature can be seen in the covered cooker.

37

5. Appendix5.1 Appendix I: Water Purifier5.1.1 Minimum UV Light to Destroy ContaminatesExamples of the ultraviolet energy required for complete destruction of some organisms [North America Aqua Environmental, LLC].

Bacteria:Clostridium tetani (tetanus/lockjaw) …………………………………………20,000 mwsec/cm2

Corynnebacter1um diphther1ae (dipther1a) .........................................................................6,500 mwsec/cm2

Mycobacterium tuberculosis (TB) ......................................................................................10,000 mwsec/cm2

Sarcina lutea .......................................................................................................................26,400 mwsec/cm2

Shigella paradysenteriae (dysentery) …………………………………………3,400 mwsec/cm2

Virus Organisms:Inf1uenza ………………………………………………………………………..6,600 mwsec/cm2

Polio Virus Type …………………………………............................................16,270 mwsec/cm2

Mold Spores:Penicillium roqueforti ……………………………............................................26,400 mwsec/cm2

5.1.2 Water Purification System Design

5.1.2.1 The Complete Water Purifier ProcessThe complete water purification system will have two segments Segment-A and Segment-B (see appendix 5.20)

Segment-A: The number/shape/material of sections comprising the column can vary. It will have two polyvinyl chloride (PVC) cylindrical sections. Water is poured through the top section and allowed to move, via gravity, downwardly through the lower section and out an outlet disposed in the lower portion which is connected to an inlet of Segment-B. The respective sections would be constructed of high-density plastic that will withstand a 15 mph drop [US 2006/0180550 A1].

Segment-A is primary use to remove arsenics from the water. All functions of the Segment-A described in the following:

Zeolite: it can be housed or contained within one of the porous containers, and would function as a filtering media and would also function to partially remove ions. It is pellet form and approximately 150 mesh sizes, which would allow an adequate flow of water therethrough and provide sufficient contact time in a gravity flow situation for the removal of nitrogen based compounds as well. This size zeolite would also allow for the removal of suspended solids from the water.

38

Cupric oxide/ARTI-64: This water treating composition will remove arsenic as As3 and As5 from water.

Segment-B: Water flow through Segment-A to Segment-B to provide a purification system capable of decontaminating water making it suitable for human consumption which includes:

Preliminary filter that will remove sand, silt, sludge, and other particulate matter Polishing carbon filtration with pore size of 0.5 microns to remove taste, odor, organic

compounds and bacterium Phosphate crystal filter to remove calcium UV chamber to received 30,000 microwatt seconds per square centimeter of UV light

minimum which is a higher level of exposure that is needed to kill bacterium [Patent# 4,849,100]

The complete water purification system will have two segments (Fig. 1a):

Segment-A. US Patent Pub. No.: US 2006/0180550 A1Segment-B. US Patent Number: 4,849,100 or

Responder A (Aqua Sun International)

\

Figure A.I.1: Water Purification System

Summary of Segment-A Summary of Segment-BThis invention to provide a water purification system that can be Portable water purifier for filtering or

treating water comprising a column, Comprises a plurality of staked sections

together in end-to-end relationship, Poured into the top of the column, the

water flows through the individual sections of the column and over a plurality of different water composition contained within the respective sections.

This invention to provide a water purification system that can be Powered by A.C. or D.C. source and

portable, Operate with its external case closed, Implementing an ultraviolet (UV) light

source, Monitors the intensity of the UV light

source, and Capable of decontaminating water making

it suitable for human consumption.

39

Segment-ASegment-B

Table A.I.1 – Water Purifier Design Segments Summary

40

5.2 Appendix II: Solar/Wood Cooker5.2.1 Irradiation Map of Africa (PVGIS, 2008)

Figure A.II.1 – Irradiation Map of Africa

5.2.2 Solar Cooker Efficiency

Where Eo is the energy output of the solar cooker in W; mw is the mass of the water in kg; cpw is the specific heat of the water in J/kg K; Twi and Twf are initial and final temperatures of the water in K; and t is the time in s.

5.2.3 Solar Cooker Performance Factor

The concentration of the cooker will be (Fp +1). (Algifri, 2001)

5.2.4 Solar Cooker Cost CostHeating Coil $40.00Temperature Controller $100.00Glass $50.00Reflectors $300.00Inner and outbox $300.00Insulation material $30.00Fasteners and Miscellaneous $50.00Total $870.00

Table A.II.1 – Solar Cooker Cost

41

5.2.5 Solar Cooker Weight

Weight [kg]Heating Coil 3Temperature Controller 2Glass 7Reflectors 18Inner and outbox 30Insulation material 2Fasteners and Miscellaneous 1Total 63

Table A.II.2 – Solar Cooker Weight

5.2.6 Solar Cooker CalculationPerformance factor Cook Time Water mass Density of

waterVolume Water

1 4 hrs 6000 g 1000 kg/m^3 0.006 m3

14400 s 6 kg 6 L

Heat Capacity Water ∆T Energy Needed Power Needed

Area Needed

4186 J/kg-K 75 K 1883700 J 130.8125 W 0.581388889 m2

1883.7 kJLength of each side (if

square)Heating Element

Efficiency

Heating Element Needed

0.762488616 m 0.98 533.9285714 W 2.501725148 ft

Table A.II.3 – Solar Cooker Calculations

5.2.7 Electric Generation Flow Rates (Calculations)Electric Generation 6kW

Fuel

Mass Flow Rate (g/s)

Volumetric Flow Rate (L/s)

JP-8 0.39 0.0003

Table A.II.4 – Electric Generation Flow Rate – 6kW

42

Electric Generation 2kW

FuelMass Flow Rate (g/s)

Volumetric Flow Rate (L/s)

JP-8 0.13 0.0001

Table A.II.5 – Electric Generation Flow Rate – 2kW

5.3 Appendix III: Power Generation5.3.1 Solar Power System (Sample Calculations)

1. Load Size

Watts Hrs/Wk Wh/Wk

Water Purifier, Solar Cooker etc. 1200 W 72 25,200

Lighting & Communication 500 W 56 6720

Total Wh/Wk 31,950

Table A.III.1 – Load Size

2. Weekly Power

AC watt hous per week after inverter loss=31 , 950 WhWk

×1.2=¿38,340 Whwk

3. Amp-Hours in a day

Inverter DC Input Voltage=24 V

Amp− Hrweek

used by AC Loads=38,340 Wh

day24VDC

=1597.5 Ahwk

Amp−Hourday

=

1597.5 Ahwk

7 daywk

=228.2 Ahday

4. Array Sizing

Battery Charge∨Discharge Compensating Factor=1.2

43

The loss ¿battery chargedischarge

=228.2 Ahday

×1.2=273.8 Ahday

Average sunhous per day∈ Africa=5.56 SH (19 with LCPV )

Total Solar Array Amps=273.8 Ah /day19 SH

=14.4 A

Maximum Amps of Solar Panel=8.65

Number of Solar Panels=14.4 A6.55 A

=2.24=3

5. Battery Sizing

Daily Amp−Hour Requirment=1116.8

Number of Consecutive Cloudy Weather Days=1 Day

Amount of amp−hour need¿ store∈the system=1116.8 Ah×1 Day=1118.8 Ah

The storage needed by the depthof discharge=390.88 Ah0.5

=781.76 Ah

Total Battery Capacity=781.76 Ah×1.04=813.0304

Battery Chosen :SAFT NHE−MH 12 v100 Ah

Number of Batteries wired∈¿=813.0304 Ah100 Ah

=4.13=5

Number of Batter ies wired∈series=24V12

=2

Number of Batteries Required=1 0

5.3.2 Wind Power System (Sample Calculations)2.1 Load Size (Refer to Appendix 1.1)

2.2 Battery Sizing (Refer to Appendix 1.5)

2.3 Wind-Turbine Sizing

44

Power=12

(density )(Swept Area) ( Power Coefficient ) (Volume )3

⟶Swept Area= Power0.5× density × Power Coefficient ×Volum e3

⟶Swept Area= 2000

0.5× 1.13 kgm3 × 0.4 × (6.5 )3

=31.47 m2

Area=π4

D2

⟶ Rotor Diameter=√ 4× Swept Areaπ

⟶ Rotor Diameter=√ 4×31.47 m2

π⟶ Rotor Diameter=6.33 m

5.3.3 Solar-PV System Location Parameterso Location: W Africa Senegal, Dakar o Latitude: 14° 38' No Longitude: 17° 27' W

o Year Average: 5.56 kWh/m2/day o Air Density: 1.235 kg/m³

Table A.III.2 – Solar Power System Parameter

45

Average Irradiance kWh/m2/day

January 4.63February 5.03March 5.46April 5.13May 5.01December 5.15July 5.7August 6.7September 6.56October 6.56November 5.77June 4.84Year Average 5.56

5.3.4 Wind-Power System Location Parameters

Figure A.III.1 – Wind Power System Parameter

5.3.5 Power Generation: Cost, Packaging, and Power Curves:Design 1 – 3.5 kW Power System

a. Packaging Previous Design Improved Design

Parts Qt Volume (m3)

Net Weight (kg)

Qt Volume (m3)

Improved Weight

(kg)Solar Panels 39 2.913 780 28 2.024 560Controller 1 0.028 6.4 1 0.028 6.5Inverter 1 0.067 17.5 1 0.067 17.5Battery 12 0.439 900 48 0.439 892.8

Fossil Fuel Generator

1 0.324 190.1 1 0.438 120

Total 3.771 1894 2.995 1597

Table A.III.3 – Design 1 Power Generation Packaging

46

b. Economy Previous Design Improved Design

Parts Qt Cost ($) Qt Cost ($)PV modules 28 $20,757.52 3 $18,826.35

Charge Controller 1 $580.00 1 $580.00Inverter 1 $500.00 1 $500.00Battery 48 $24,000.00 10 $7200.00

Communication 1 $ 16,000.00 1 $ 16,000.00

Total Cost $50,837.52 $37,040.5

Table A.III.4 – Design 1 Power Generation Economy

Design 2 - 3.5 kW Power System

c. Packaging

Previous Design Improved Design

Parts Quantity Volume (m3)

Net Weight

(kg)Quantity Volume

(m3)

Net Weight (kg)

Wind Turbine +

Blades

Generator 1 0.368425

1 0.286416

Blades 0.6162 0.456

Hydraulic Free

Standing Tower (12

m)

1

1408

1

1408

Upper Section 0.008 0.008

Middle Section 0.0154 0.0154

Bottom Section 3.405 3.405

Tower Base

Inverter 1 .0936 93 1 0.0936 38.5

Controller 1 1.777E-4 70 1 1.777E-

4 50

Battery 20 0.732 1190 20 0.186 372Generator 1 0.324 190.0 1 0.197 120

Total 5.56 3376 4.64 2404.5

Table A.III.5 – Design 2 Power Generation Packaging 47

d. Economy

Previous Design Improved DesignParts Qt Cost ($) Qt Cost ($)

Wind Turbine (Charge Controller included)

1 $20,000.00 1 $10,000.00

Hydraulic Towers 1 $10,000.00 1 $10,000.00Inverter 1 $3,999.00 1 $2,999.00Battery 20 $12,000 20 $10,000.00

Generator 1 $7000.00 1 $5000.00

Total Cost $52,999.00 $37,999.00


e. Power Curve

Figure A.III.2 – Design 2 Power Curve

Design 3 – 2 kW Power System

Packaging

Previous Design

Improved Design

Parts

Quantity

Volume (m3)

Net Weight (k

Quantity

Volume (m3)

Net Weight (k

48

g)

g)

Wind Turbine + Blades

Generator

1

0.286 4

16

1

0.286 4

16Bl

ades

0.6162

0.456

Hydraulic Free Standing Tower (12

m)

1

1408

1

1408

Upper Section

0.008

0.008

Middle

Section

0.0154

0.0154

Bottom Section

3.405

3.405

Tower Base

Inverter

1

.0936

93 1

0.0936

38.5

Controller

1 1.777E-

70

1 1.777E-

50

49

4 4

Battery

20

0.732

1190

20

0.186

372

Generator

1

0.169

64 1

0.169

64

Total

5.32

3241

4.62

2348.5


f. Economy Previous Design Improved Design

Parts Qt Cost ($) Qt Cost ($)Wind Turbine (Charge

Controller included)1 $10,000.00 1 $10,000.00

Hydraulic Towers 1 $10,000.00 1 $10,000.00Inverter 1 $1,999.00 1 $2,999.00Battery 20 $12,000 20 $10,000.00

Generator 1 $1800.00 1 $1800.00

Total Cost $35,7999.00 $34,799.00


g. Power Curve

50

Figure A.III.3 – Design 3 Power Curve

Design 4 - 2 kW Power System

h. Packaging

Previous Design Improved DesignParts Qt Volume

(m3)Net Weight

(kg)Qt Volume

(m3)Improved

Weight (kg)

Solar Panels 13 0.971 260 17 2.024 340Controller 1 0.028 6.4 1 0.028 6.4Inverter 1 0.067 17.5 1 0.067 17.5Battery 4 0.146 300 28 0.439 520.8

Fossil Fuel Generator

1 0.169 64 1 0.169 64

Total 1.381 647.9 1.748 948.7


i. Economy

Previous Design Improved DesignParts Qt Cost ($) Qt Cost ($)

PV modules 13 $7,275.45 17 $12,602.78

Charge Controller 1 $580.00 1 $580.00Inverter 1 $500.00 1 $500.00Battery 4 $2,400.00 28 $14,000.00

Fossil Fuel Generator 1 $1800.00 1 $ 1800.00

Total Cost $12,555.45 $29,482.78


5.5 Appendix V: Technical and Environmental Analysis (Design 1)5.5.1 Thermal-Fluid Specifications

5.1.1.1.1 Water Purifier MaintenanceThe maintenance of purifier is very simple. The approximate water amount produced with newer water purifier or replacement parts kit is about 40,000 gallons or 148,000 liters (Approximately 1 year all parts except UV bulbs about 2 years).

51

Replacement Parts Kit Quantity includes 4 - Washable / Reusable Debris Filter, 4 - 5.0 micron Sediment Filters, 4 - 0.5 micron Carbon Block Filters and 1 - Ultraviolet Bulbs.


5.5.1.2 Solar CookerIt was assumed that the average solar radiation in the horizontal plane was 450W/m2. This assumption was based on the total solar radiation that regions in Africa receive. A map and calculation of solar radiation can be found in the appendix of this report.

Efficiency of solar cooker is defined as energy needed to raise the temperature of water over the energy incident on the cooker (See appendix for complete definition) (Ozturk):

Similar cooker designs found in the literature reported efficiencies as high as 61% and as low as 20% (Funk 2000). A conservative estimate of 25% efficiency was assumed for the solar cooker. A cook time of four hours was assumed for the cooker. The increased radiation on the cooker from the reflector plates is calculated from a performance factor (See appendix for performance factor definition). A performance factor of one was assumed for the solar cooker.

A heating element will be used to cook food when solar energy is unavailable. A 650W electric heating element on the bottom of the cooker will provide heat. The heating element will be powered 120VAC drawing at a maximum 5.4A. The efficiency of the heating element was assumed to be 98%.

The pressure inside the solar cooker is assumed to be atmospheric pressure. The box is not air tight meaning air is free is escape. The temperature inside the cooker can be estimated around 120 C. Based on energy calculations it was found that 0.6m⁰ 2 of window area is needed. A square design of the solar cooker was considered with the length of each side equal to 0.8m. The window will sit at angle close to 45 with respect to the horizontal.⁰

Reflectors will also be square and made of polished 20 gauge stainless steel. Mounted on hinges the reflectors will be able to fold up for transportation. With the reflectors folded away the overall dimensions of the cooker are: 0.8m x .57m x .57m

5.5.1.2.1 Solar Cooker MaintenanceSolar cook maintenance will be very similar to a traditional household oven with the expectation that the oven window will need to be cleaned after each use. A standard window cleaner will be used to remove any contaminates from the solar window. Any dirt built up will reduce the solar energy transmitted through the window. Less than five minutes of cleaning will be required before use.

Other than cleaning, solar cooker maintenance is minimal. The cooker will have a widow designed to maintain transparency for up to four years. The oven’s heating element will be designed robustly enough to last the lifetime of the product.


52

5.5.1.3 Solar Power System

5.5.1.3.1 Solar Power System - 6kW (Original Design)A PV array consists of number of PV module, which is environmentally sealed group of PV Cells. PV Cells are the essential mechanism of the PV power system that converts the sunlight into electricity. Based on the design load, 39 pieces of solar module will make a PV array to produce 6kW at average sun hours of 5.56 in Africa. Evergreen ES PV panels were selected to generate 6kW.

A battery bank is used to is store energy in the batteries for certain amount of days in order to have available power when there is little sunlight such as on cloudy days or during nighttime. Total 12 of Concorde Solar battery, discharging at a depth of 50%, will be used to backup power for about 8 hours. There is two groups that are connected in series, each group has 6 batteries are connected in parallel. Each Concord PVX-2580L has a voltage of 12VDC, and nominal capacity ampere-hours of 258Ah. The fossil fuel generator comes in operation when the wind power system fails to produce the required power to support the house loads. Cummins Onan Commercial Generator QD 6000 operating at 60Hz, 120VAC, & 50A produces 6000 Watts. It will be used as a backup generator for this system.

Note: For 6 kW power consumption chart, array sizing and Evergreen panels specification, refer to Appendix 7.3

In PV system, the charge controller performs the task of maintain the charging voltage across the batteries. When solar cells produce more voltage due to intense daylight, the batteries can be damaged due to excessive voltage. Outback Flexmax 60 controller regulates the voltage for the system. It is rated at 12~60 VDC for 60A. As the system voltage is 24VDC, Outback Flexmax will adequately work for the system. An inverter is a tool that converts a DC voltage to AC voltage. It is essential for the PV system as the energy from PV array is stored in low voltage DC batteries. Univ-5000P off-grid inverter generates a 5000 kW output power and 110/220 VAC output voltage. The inverter has the system voltage as its input voltage of 24VDC.

5.5.1.3.2 Solar Power System – 1 kW (Improved Design)A solar power system consists of PV-array, charge controller, battery bank, and an inverter. In previous design to produce 6kW, the PV-array consisted of 12 pieces of Sharp PV solar module weighing 20 kg each, and battery bank (for 24 hours of backup) had 12 Concord PVX-2580L batteries weighing 75 kg each. The Evergreen solar panels were rated at 11.38 amps and the Concord batteries were rated at 12 Volts and 250 Ah. The improved design is proposed to produce 1 kW of power.

5.5.1.4.3 Solar Power System MaintenanceThe maintenance for solar system includes the module array cleaning, dc-electrical check (controller and batteries), inverter & main distribution board preventive maintenance, and energy production analysis & reporting. Because of the durability of diesel engines, preventive maintenance consists of general inspection, lubrication service, cooling system service, fuel system service, and regular engine exercise.


53

5.5.2 Environmental Considerations

5.5.2.1 Water Purifier Water purifier is environmental affable, built-in flexibility, and easy to operate devices. In this design, PVC pipe (most commonly used in water systems) is used which does not rust, rot, or wear over time. PVC Plastic and stainless steel that are used in this design are durable, hard to damage, long lasting and recyclable. Arsenic consumption leads to higher rates of some cancers, including tumors of the lung, bladder and skin, and other lung conditions [BBC News]. So, it is very important to remove arsenics from drinking water. Segment-A is added to this water purifier to remove arsenics from the drinking water.

5.5.2.2 Solar CookerSolar cookers are environmentally friendly devices. They emit no CO2 or any other harmful emissions. The cooker is reusable for many years. At the end of its life cycle the majority of the materials including glass and steel can be recycled.

5.5.2.3 Solar GenerationSolar/wind electric systems or photovoltaic (PV) have little environmental impact, making them one of the cleanest energy technologies available today. While operating, PV systems produce no air pollution, noise pollution, greenhouse gas emissions, or hazardous waste. Investing in a PV system allows one to play an active role in mitigating environmental problems such as global warming, air pollution, and the devastating effects of strip mining. The electric generation have lead-acid batteries are the environmental success story of our time. Roughly 96 percent of all battery lead is recycled. Compared to newspapers, aluminum cans and glass bottles, lead-acid batteries top the list of the most highly recycled consumer product. The lead-acid battery gains its environmental edge from its closed-loop life cycle. The typical new lead-acid battery contains 60 to 80 percent recycled lead and plastic. When a spent battery is collected, it is sent to a permitted recycler where, under strict environmental regulations, the lead and plastic are reclaimed and sent to a new battery manufacturer. The recycling cycle goes on indefinitely. That means the lead and plastic in the lead-acid battery in your car, truck, boat or motorcycle have been - and will continue to be recycled many, many times.

5.6 Appendix VII: Public Awareness/Community Outreach PlanThere are a few different plans of action in order for our relief kit. The first is to get the public to understand and become aware of the design, use, and effectiveness of this project. The second is to set up a Community Outreach program.In order to get the public aware of the Relief kit, our team has a plan that will include the following:

1. Develop and distribute a Relief Kit Newletter2. Develop and provide speakers on the Relief Kit to military and companies that are

interested in humanitarian relief3. Develop and maintain a Relief Kit webpage4. Prepare press releases

54

5. Conduct a trade show that would allow companies to showcase their humanitarian relief products

55

5.7 Appendix VI: Complete Maintenance Information and Costs

DESCRIPTION LIFE EXPECTANCY Maintenance Task Interval CostMaintenance Annual

CostTotal

Annual Change HVAC Filter 30 Days 17.97

Solar Power: Module array cleaning, dc-electrical check (controller and batteries), inverter & main distribution board preventive maintenance,

and energy production analysis & reporting.$2,000.00 Adjust Tent Guide

Cables Daily 0

Make sure tent stakes are secure Daily 0

WASHABLE / REUSABLE Pre-FILTER:

Solar Power: Module array cleaning, dc-electrical check (controller and batteries), inverter & main distribution board preventive maintenance,

and energy production analysis & reporting.$1,200.00

SEDIMENT FILTER:

0.5 micron CARBON BLOCK with CYSTS AND VOC’S REDUCTION:

Maintenance Annual Cost

Total Annual

O&M Cost

Wind Power: Oiling and greasing, and regular safety inspections. Check bolts and electrical connections annually; tighten if necessary. Once a year check wind turbines for corrosion and the wires supporting the

tower for proper tension.

$2,400.00

ULTRAVIOLET DISINFECTING LAMP:

Clean, safe and natural UV light rays have the ability to kill the bacteria and virus to 99.999 % purity without any harmful side

effects much like chemical agents normally added to drinking water. The ultraviolet

range is ideal for killing Micro-organismssuch as E-coli, Coli form, Cholera,

Legionnaires Disease, Hepatitis Virus, Typhoid Fever, Dysentery, Infectious

Jaundice,


Total Annual

O&M Cost

Influenza, Enteric Fever and many other unwanted Microorganisms. Wind Power $2,400.00

*Diesel Generator: Same as above. $150.00

Removes river and lake water particles such as leaves, twigs, sediment and protects the

sediment pre-filter from premature clogging. This filter is easily washed and cleaned

when clogged. Attaches to inlet hose end when heave sediment is present.


Total Annual

$1,420.00

Diesel Generator:preventive maintenance consists of general inspection, lubrication service, cooling system service, fuel system service, and

regular engine exercise. $500.00

2 kW Wind-Diesel Power System O&M Cost

Diesel Generator:preventive maintenance consists of general inspection, lubrication service, cooling system service, fuel system service, and

regular engine exercise. $500.00

The oven’s heating element will be designed robustly enough to last the lifetime of the product.

The wood stove will need to be cleaned of

ash after each use. After about a month

of use a more thorough cleaning of

the oven will be required. The walls and chimney will

need to be scraped of any build up.

After each use. Every month clean the

chimney.

A small shovel included with the stove will be

used to remove the ash out of the combustion chamber. The use of a

solvent may be necessary for the chimney.

Maintenance Description Time Interval Tools needed for

maintenance

Solar Cooker Total Maintenance cost:$50 per year

Wood CookerMaintenance Task and Interval Cost

$2,500.00

Removes and reduces giardia lamblia and cryptosporidium cysts, volatile organic

chemicals "VOC's" pesticides and herbicides, turbidity reduction, sediment,

color, bad taste and odors such as hydrogen sulfide "rotten egg smell" and many other

microorganisms down to a 0.5 micron. This Carbon Block Filter polishes the water crystal clear for refreshing good tasting

water. This filter is made entirely from FDA-compliant materials.

APPROXIMATE UV BULB LIFE EXPECTANCY 8000

hours, or approx 12 – 18 months.

APPROXIMATE FILTER LIFE EXPECTANCY 10,000 gallons / 37,000 liters or one year of clean incoming water

maximum.

APPROXIMATE FILTER LIFE EXPECTANCY depends on how dirty

incoming water is or 1 year maximum.

Removes ground water sediment and protects the carbon block filter from premature clogging. Not washable.

Wind-Diesel Power System O&M

3.5 kW Wind-Diesel Power System O&M Cost

The entire Chillii PSC12 kit, including the; cooling tower, controller, and chiller, is all under a lifetime warrenty when

purchased. Any maintenace needed will need to be conducted by a trained professional in the maintenance of the Chillii

PSC12 kit. The chiller itself is considered very low maintenance because it does not not used and pumps or

mechanical systems within the device. It is made of robust piping within a closed system. A trained professional should

be called to inspect each kit after every 2 years of use.

$2,550.00 Total Maintenance Cost: Approximately, $410.00 per year

*Diesel Generator:preventive maintenance consists of general inspection, lubrication service, cooling system service, fuel system

service, and regular engine exercise.

$220.00

Absorption System: Chillii PSC12 Kit with Wood Boiler

APPROXIMATE FILTER LIFE EXPECTANCY depends on how dirty

incoming water is or 1 year maximum

2 kW Solar-Diesel Power System O&M Cost

Total Maintenance Cost: $18.00/month

General Inspection (look for holes, rips, tears,

debris)Daily 0

COMPLETE MAINTENANCE INFORMATION

Maintenance Description

Tools needed for maintenance

Time Interval

The oven window will need to be

cleaned.

After each use. Less than five minutes of

cleaning will be required before use.

WATER PURIFIER Solar-Diesel Power System O&M Solar Cooker

A standard window cleaner will be used.

SEGMENT A

SEGMENT B

HVAC AND TENT3.5 kW solar-Diesel Power System Maintenance Cost

APPROXIMATE LIFE EXPECTANCY depends on how dirty incoming water is or 5,000 gallon or 6 month

maximum.

Zeolite & Cupric Oxide/ARTI-64: Remove arsenics and heavy metal

$2,900.00

Wood Cooker Total Maintenance cost:$150 per year

Total Maintenance Cost: Approximately, $20/year

The entire stove and chimney inside the wood boiler will need to be cleaned

thoroughly every month. A small shovel included with the stove will be

used to remove the ash out of the combustion chamber. The use of a

solvent may be necessary for the chimney.

The cost will vary according to different

brands of cleaning supplies used. An

estimated cost would be roughly 20 USD.

Other components of the wood stove will be designed to last for the lifetime of the product.

The seals on the door of the combustion chamber and stove

will need to be replaced.

After every year of use.

Replacement seals can be installed without use of

specialized tools.

56

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Algifri, A, (2001) “ Efficient orientation Impacts of Box-type solar cooker on the Cooker Performance,” Solar Energy, Vol 70, No.2 pp. 165-170

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Cabelas (2010) “Disc-O-Bed Cam-O-Cot Bunk Beds”, Cabelas. <http://www.cabelas.com/product/Camping/Cots-Pads-Beds/Cots%7C/pc/104795280/c/104712480/sc/104280480/Disc-O-Bed-Cam-O-Cot-Bunk-Beds/735034.uts?destination=%2Fcatalog%2Fbrowse%2Fcamping-cots-pads-beds-cots%2F_%2FN-1100677%2FNs-CATEGORY_SEQ_104280480>.

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Dounis, A.I. and Manolaskis, D.E., (2001), “Design of a Fuzzy System for Living Space Thermal-Comfort Regulation” Applied Energy, 69, p119-144

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Funk, P, (2000) “Evaluating the International Standard Procedure for Testing Solar Cookers and Reporting Performance,” Solar Energy, Vol 68, No. 1 pp. 1-7

Hanson, Greg (1993) “Responder A – Water Purification System”. www.aqua-sun-intl.com.

Hill, R., (1977) “Design, Construction and Performance of Stick-Wood Fired Furnace for Residential and Small Commercial Application,” Department of Energy, pp. 19Incropera, Frank P. (2007) “Fundamentals of Heat and Mass Transfer” 6th Edition, John Wiley & Sons

“IEEE Guide for Array and Battery Sizing in Stand-Alone Photovoltaic (PV) Systems).” (2008) IEEE Standards, IEEE Std. 1562-2007, IEEE INSPEC # 10150619

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Documents

Pre-positioned Expeditionary Assistance Kits (PEAK) Including