Engineering, Design & System Integration 3,000 HP Wind Tunnel ...

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Engineering, Design &

System Integration

3,000 HP Wind Tunnel

Blower, Motor, VFD &

PLC Control System

OEA PRESENTATIONDecember 1, 2016

Philadelphia, PA

P 215.542.8700 F 215.542.5652

Visit us online

www.Maidaeng.com

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PROJECT CRITERIA

Engineering, Design and System Integration

� Subcontractor to Aerolab to provide a “Turnkey” Open Jet Wind

Tunnel Air Delivery System for Honeywell

� Responsible from Concept through Commissioning

� Designed in Philadelphia, PA and Built in Mexicali, Mexico.

� Components and Systems

� 415,000 CFM Blower with Dampers and Silencers

� 3,000 HP Medium Voltage Motor

� Coupling (Drive Train)

� 3,000 HP Medium Voltage Variable Frequency Drive

� PLC Based Monitoring and Control System

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PROJECT ANALOGY

Would be similar to a 3,000 HP Vehicle

� Runs at speeds from 0 MPH to 230 MPH, + 1 %.

� Can go from 230 MPH to 0 MPH in less than 18 seconds.

� Can operate continuously in an ambient temperature of 125°F

� Designed for Seismic Zone 4

� Custom Dashboard (HMI)

� Cruise Control

� Has a life expectancy of 25 year.

� Comes with a One to Four Year Warrantee

� Global Procurement and Assembly of Custom Components

� Runs like a Well Designed Machine

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PROJECT EXECUTION

SCHEDULE

Conceptual Engineering June to Sept, 2015

Blower, Motor and VFD Procurement Sept to Nov 2015

Factory Inspections March to June 2016

Detailed PLC Panel Installation Design Feb to June 2016

WTC/PLC Fabrication Procurement May 2016

Equipment Shipped to Mexico June and July 2016

Equipment and System Installations June to Nov 2016

PLC Programming and HMI Screens Aug to Nov 2016

Site Inspections and Acceptances June to Nov 2016

Commissioning ` Oct and Nov 2016

Warrantee Through Nov 2017

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CONCEPTUAL ENGINEERING

Concept:

Proposed 4 alternative

arrangements and

based on discussions

with the client, selected

the this arrangement.

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PROCUREMENT

Equipment Specifications and Selection

� Approach

� Performance Criteria

� Installation Criteria

� Desired Equipment Subcomponents

� Bearings – Blower and Motor

� Silencers - Blower

� Actuators - Blower

� Instrumentation – Blower, Motor and VFD

� Cooling Systems – Motor and VFD

� MV Input and Output Disconnects - VFD

� MV and LV Terminal Boxes – Motor and VFD

� Shafts

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DESIGN AND ANALYSIS

�Studies:

�Power Flow

�Torsional Analysis

�Harmonic

Analysis

�Coordination

�Arc Flash

�Coordination

�Aerolab

�Manufacturers

�Packaging

�Shippers

�Building Design Firm

�Contractors

Engineering Requirements – Maida’s Responsibility

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FAT AND SHIPPING

415,000 CFM Blower - Parts

built in Tennessee and

elsewhere were assembled in

Mexico

FACTORY INSPECTION, PACKAGING AND SHIPPING

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FAT AND SHIPPING

Came together for 1st time in

Mexicali, Mexico

3,000 HP, 4 KV TEWAC

Motor – Built in Helsinki,

Finland

3,000 HP, 4.16 KV

VFD Built in New

Berlin, Wisconsin

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FAT AND SHIPPING

WTC/PLC Control Panel –

Built in Bethlehem, PA

PLC System –

Programmed in

Philadelphia

FACTORY INSPECTION, PACKAGING AND SHIPPING

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DESIGN AND ASSEMBLY

Mechanical

Procurement

� Blower

� Coupling

� Damper

� Damper Actuator

Mechanical Design

�Wall Air Filters

� Cooling Water

System

� Foundation Details

� Baseplates

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FOUNDATION - PEDESTAL

BLOWER BUILDING

MAJOR EQUIPMENT

ARRANGEMENT

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FOUNDATION – BED PLATES

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AIR FILTERS

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DETAILED DESIGN

5 KV VFD MOTOR BRANCH CIRCUIT

INSTALLATION DETAIL

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DESIGN AND ASSEMBLY

Electrical Procurement

� 3,000 HP Motor

� 3,000 HP VFD

Electrical Design

� 5 KV VFD Branch

Circuit

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WTC/PLC PANEL

WTC/PLC Panel

Design

Procurement

Programming

Commissioning

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INSTRUMENT AND CONTROL

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DETAILED DESIGN

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PLC PROGRAM & HMI SCREENS

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OEA AWARD CRITERIA

� Demonstrates engineering challenges and

innovative solutions

� Integrate a Blower, Motor and VFD that will

perform as required under harsh conditions

with no mistakes, thereby enabling

Honeywell to maintain its commitments.

� Modify commercially available equipment to

meet the operational requirements of the

wind tunnel.

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OEA AWARD CRITERIA

� Demonstrates the importance of the

engineering profession to society

� The wind tunnel will be used for

performance and endurance testing of

equipment enhancing the safety of large

commercial and military aircraft.

� The wind tunnel would not exist without the

blower, motor, VFD and PLC System which

are engineered products and systems.

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OEA AWARD CRITERIA

� Demonstrate a clear and tangible benefit to

the Delaware Valley Region 2.

� Local engineering and design talent

enabled us to perform this project without

no issues, within schedule and within

budget.

� Awaiting future turnkey projects to design

and build the power and control systems for

many more 2,000 to 3,000 HP Wind

Tunnels in the next five year.

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OEA AWARD WINNER

LOW SPEED OPERATION

Smoke 1.m4v

Smoke 2.m4v

QUESTIONS

Engineering, Design & System Integration 3,000 HP Wind Tunnel ...

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