Pre-positioned Expeditionary Assistance Kits (PEAK)
Including: Power Generation, Robust Water Purification,
Communication, and Cooker Systems
MS4 Final Report
Prepared by:
Era Raizada
Eric Gingrich
Waleed Al-Taie
Roslayn Warner
Bruce 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
1
Executive Summary
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, offthe-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.
2
Table of Contents
1. Problem Statement ...................................................................................................................... 6
1.1 Background .................................................................................................................... 6
1.2 Specifications ................................................................................................................. 6
1.3 Constraints ...................................................................................................................... 7
1.4 Criteria ............................................................................................................................ 7
1.5 Testable Requirements ................................................................................................... 7
2. Alternative Design Concepts ...................................................................................................... 8
2.1 Significant Features of the Alternative Designs ............................................................. 8
2.2 Overall Schematics of Subsystems and Components..................................................... 9
2.2.1 Design 2 ......................................................................................................... 9
2.2.2 Design 3 ....................................................................................................... 12
2.2.3 Design 4 ....................................................................................................... 13
2.3 Energy and Environmental Analyses ........................................................................... 14
2.3.1 Design 2 ....................................................................................................... 14
2.3.2 Design 3 ....................................................................................................... 14
2.3.3 Design 4 ....................................................................................................... 14
2.4 Packaging Breakdown .................................................................................................. 15
2.4.1 Design 2 ....................................................................................................... 15
2.4.2 Design 3 ....................................................................................................... 16
2.4.3 Design 4 ....................................................................................................... 16
2.5 Economic Analyses ...................................................................................................... 17
2.5.1 Initial Purchase Cost .................................................................................... 17
2.5.2 Annual Maintenance Cost ............................................................................ 18
3. Decision Making & Presentation of the Proposed System ....................................................... 19
3.1 Technical Analysis ....................................................................................................... 19
3.1.1 Water Purifier............................................................................................... 19
3.1.2 Solar Cooker ................................................................................................ 20
3.1.3 Solar Power System ..................................................................................... 21
3.2 Decision Making Analysis ........................................................................................... 22
3.3 Final Design: Overall Schematics of Subsystems and Components ............................ 23
3.4 Mass and Energy Flow of Subsystems and Components ............................................. 23
3.5 Packaging and Installation............................................................................................ 26
3.6 Materials and Economic Analysis ................................................................................ 28
3.6.1 Initial Purchase Cost .................................................................................... 28
3
3.6.2 Annual Maintenance Cost ............................................................................ 28
3.7 Safety Analysis of the Final Design ............................................................................. 28
3.7.1 Water Purifier............................................................................................... 28
3.7.2 Solar Cooker ................................................................................................ 29
3.7.3 Power Generation: Solar Power ................................................................... 30
3.8 Features & Operations .................................................................................................. 32
4. Design Analysis & Verification ................................................................................................ 33
4.1 Photovoltaic Power System Analysis ........................................................................... 33
4.2 Solar Cooker Design Analysis ..................................................................................... 34
4.3 Solar Cooker Verification ............................................................................................ 34
4.3.1 Model Conditions......................................................................................... 35
4.3.2 Material Properties ....................................................................................... 35
4.3.3 Boundary Conditions ................................................................................... 36
4.3.4 Calculations.................................................................................................. 36
5. Appendix ................................................................................................................................... 38
5.1 Appendix I: Water Purifier ........................................................................................... 38
5.1.1 Minimum UV Light to Destroy Contaminates ............................................ 38
5.1.2 Water Purification System Design .............................................................. 38
5.2 Appendix II: Solar/Wood Cooker ................................................................................ 40
5.2.1 Irradiation Map of Africa (PVGIS, 2008).................................................... 40
5.2.2 Solar Cooker Efficiency............................................................................... 40
5.2.3 Solar Cooker Performance Factor ................................................................ 40
5.2.4 Solar Cooker Cost ........................................................................................ 40
5.2.5 Solar Cooker Weight.................................................................................... 41
5.2.6 Solar Cooker Calculation ............................................................................. 41
5.2.7 Electric Generation Flow Rates (Calculations)............................................ 41
5.3 Appendix III: Power Generation .................................................................................. 42
5.3.1 Solar Power System (Sample Calculations) ................................................ 42
5.3.2 Wind Power System (Sample Calculations) ................................................ 43
5.3.3 Solar-PV System Location Parameters ........................................................ 44
5.3.4 Wind-Power System Location Parameters .................................................. 44
5.3.5 Power Generation: Cost, Packaging, and Power Curves: ........................... 45
5.4 Appendix V: Technical and Environmental Analysis (Design 1) ............................... 49
5.4.1 Thermal-Fluid Specifications....................................................................... 49
5.4.2 Environmental Considerations ..................................................................... 51
4
5.5 Appendix VII: Public Awareness/Community Outreach Plan ..................................... 52
5.6 Appendix VI: Complete Maintenance Information and Costs .................................... 53
6. References ................................................................................................................................. 54
5
1. Problem Statement
1.1 Background
Design 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 Specifications
The following table will explain the overall PEAK system design specifications. The detailed
specifications for each design will be listed under each specific component.
Location
Overall Power Generation
East Africa
Must be relying on the renewable resources
Electricity
Power Consumption
Water Purifier
Filtered contaminants
Polishing
Remove
Power Source
Water Supply
Cooker
Power Supply
Secondary Power Supply
Heating Capacity
110V / 220V and 60 Hz
1kW (Max)
Microorganisms > 0.5 microns; Viruses < 0.5 microns
Carbon Filtration
Taste, Odor, Organic compounds and bacterium
Electrical
370 L water per day
Sun or Biomass
Electrical Heating Coils
6 kg of water to 100oC in less than 4 hrs
Table 1: Overall Specifications for All PEAK System Designs
6
1.3 Constraints
Completed 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 Criteria
The 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.
II.
III.
IV.
V.
VI.
Best packaging and transportability (25%):
a. Smallest size -- 10%
b. Lowest weight -- 15%
Environmental consideration (20%):
a. Best durability for environment -- 10%
b. Lowest environmental impact -- 10%
Consumption Efficiency (20%)
a. Lowest total power consumption-10%
b. Lowest gathered resources-5%
Greatest availability of technology-15%
Greatest reliability and with lowest maintenance-10%
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.
7
2. Alternative Design Concepts
2.1 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
Local and
Local and
Local and
Local and
Communication
Satellite
Access
Satellite
Access
Satellite
Access
Satellite
Access
Power Generation
Solar- 1kW
Wind- 6kW
Wind- 2kW
Solar- 2kW
8
2.2 Overall Schematics of Subsystems and Components
2.2.1 Design 2
Figure 1: Complete Design 2
2.2.1.1 Water Purifier
Water Purifier Specification
Usability
Operated Power Source
Total Power Consumption (Pump and UV)
Rated Water Pressure
Self Priming Water Pump
UV Lamp Output
UV Bulb – Life Expectancy
Sediment Filter (Pre-filter)
Carbon Block Polishing Filter
Carbon Block Polishing –
Filter Life Expectancy
Crystal Filter
Water Treating Composition (Segment-A)
Portable
110 or 220 V A.C. or 12 V D.C.
24 Watts
20 PSI minimum / 65 PSI maximum
Max. 1 gallon/min & 1.8 amps max per
hour depending on head.
30,000 𝜇𝑊𝑠 ⁄𝑐𝑚2
8000 hours, or Approx. 2 years
5.0 microns
0.5 microns
10,000 gallons or
1 year of clean incoming water max
Phosphate
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
9
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 Cooker
It was assumed that the average solar radiation in the horizontal plane was 450W/m 2. 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
120⁰C. Based on energy calculations it was found that 0.6m2 of window area is needed. A square
10
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 45⁰ with respect to the horizontal.
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 Turbine
Rated Power
5000 W
Max Power
6000 W
Output Voltage
220V-300V
Generator
3-phase, permanent magnet
Start-up Speed
2 m/s
Number 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)
Rated capacity (Ah)
Specific Energy (Wh/Kg)
Specific Power ( W/Kg)
Weight (kg)
12
100
66
150
18.5 (each)
Table 2.3 – Saft NHE Battery Specification
11
.2.2 Design 3
Figure 2: Complete Design 3
2.2.2.1 Water Purifier: Refer to Design 2
2.2.2.2 Wood Oven
The 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 150⁰C can be assumed for the lower cooking chamber. After the oven
has reached steady state the following mass and volume flow rates can be estimated:
Wood Oven Mass & Flow Rates
Wood Mass Burn Rate
Air Intake Mass Flow
Air Intake Volume Flow
Exhaust Mass Flow
Exahust Volume Flow
4.22 kg/hr
0.04 kg/s
0.033 m3/s
0.042 kg/s
0.047 m3/s
Table 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
12
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 windturbine 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
Figure 3: Complete 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 3
A 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.
13
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 Cooker
Solar 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 Generation
The 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 Cooker
Wood 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 Generation
Solar/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
14
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
Water Purifier
Solar Cooker
3.5 kW Wind-Diesel
Power System
Calculation
Segment A) V= πr2h = π*(6in)2*18in=2035.75 in3=0.03 m3
Segment B) V=22in*18in*10in=3960 in3 = 0.06489 m3
0.8m x .8m x .25m
Volume (m3)
Generator
0.286
Wind Turbine +
Blades
Blades
0.456
Upper Section
0.008
Hydraulic Tower
Middle Section
0.0154
(12m)
Bottom Section
3.405
Inverter
0.0936
Controller
1.78E-04
Battery
0.186
Fossil fuel Generator
0.380
TOTAL
Volume
(m3)
0.98530
0.160
4.8301777
6.12
Table 2.5– Design 2 Volume Information
15
2.4.2 Design 3
For 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.
Design 3 Volume Information
Component
Calculation
Volume
(m3)
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 m3
0.99
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
TOTAL
4.10
10.16
Table 2.6– Design 3 Volume Information
2.4.3 Design 4
Solar 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.
16
Design 4 Volume Information
Component
Water Purifier
Solar Cooker
Solar-Diesel
Power System
Absorption System
& Small Tent
Volume
(m3)
Calculation
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
0.8m x .57m x .57m = 0.25992m3
Volume Total
Size Each (m)
(m3)
PV panel (SHARP NU1.64* 0.958*0.046
1.22861584
U240F1)
Battery (SAFT NHE-MH
0.390* 0.195* 0.120
0.255528
12v 100Ah)
0.169
2kW Pramac Generator
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
TOTAL
0.99
0.26
1.75
4.10
7.10
Table 2.7 – Design 4 Volume Information
Component
Water Purifier
Wood Cooker
Wind-Diesel Power
System
TOTAL
Design 2
Weight
Weight
(kg)
(lbs.)
24.95
55.01
62.87
138.62
Design 3
Weight
Weight
(kg)
(lbs.)
24.95
55.01
124.74
275.05
Design 4
Weight
Weight
(kg)
(lbs.)
24.95
55.01
124.74
275.05
2404.50
2508.42
2348.50
2465.22
948.70
1265.42
5301.92
5333.56
5178.44
5463.81
2091.88
2377.25
Table 2.8: Alternative Designs Total Weight
2.5 Economic Analyses
2.5.1 Initial Purchase Cost
Design 2
Design 3
Design 4
Component
Water Purifier
Cost (USD)
Cost (USD)
Cost (USD)
$2,165.00
$2,165.00
$2,165.00
Solar Cooker
Wind-Diesel Power
System
Total
$870.00
$2,540.00
$2,540.00
$37,999.00
$34,498.00
$29,482.78
$41,527.92
$49,722.25
$38,707.03
Table 2.9: Alternative Designs Initial Purchase Cost
17
2.5.2 Annual Maintenance Cost
Design 2
Design 3
Design 4
Component
Water Purifier
Cost (USD)
$410.00
Cost (USD)
Cost (USD)
$410.00
$410.00
Solar Cooker
3.5 kW Wind-Diesel Power
System
Total
$50.00
$150.00
$50.00
$2900.00
$2620.00
$1420.00
$3176.00
$3216.00
$716.00
Table 2.10: Alternative Designs Annual Maintenance Cost
18
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 Specification
Portable
110 or 220 V A.C. or 12 V D.C.
24 Watts
20 PSI minimum / 65 PSI maximum
Max. 1 gallon/min & 1.8 amps max per hour
Self Priming Water Pump
depending on head.
UV Lamp Output
30,000 𝜇𝑊𝑠⁄𝑐𝑚2
8000 hours, or Approx. 2 years
UV Bulb – Life Expectancy
5.0 microns
Sediment Filter (Pre-filter)
Depends on how dirty incoming water is or
Sediment Filter - Life Expectancy
1 year maximum
0.5 microns
Carbon Block Polishing Filter
10,000 gallons or
Carbon Block Polishing –
1 year of clean incoming water max
Filter Life Expectancy
Phosphate
Crystal Filter
Zeolite, Cupic Oxide (ARTI-64)
Water Treating Composition (Segment-A)
Table 3.1: Water Purifier Specifications
Usability
Operated Power Source
Total Power Consumption (Pump and UV)
Rated Water Pressure
19
3.1.2 Solar Cooker
Figure 3.2: Solar Cooker
Solar Cooker Specifications
Widow size L x W (m)
Window transmissivity
0.8 x 0.8
83%
0.8 x 0.8 x
Overall Dimensions L x W x H
0.25
Maximum cooker air Temperature (⁰C)
128
128
Maximum interior surface temperature (⁰C)
Reflector Size L x W (m)
0.8 x 0.8
Reflector number
4
Reflector angles (w.r.t ground)
45⁰
Reflector Material
Steel
Table 3.2 – Solar Cooker Specifications
3.1.3 Communication
Figure 3.3: NGC Deployable Digital System
20
Manufacture
Model
Voltage
Current (amp)
Power Consumption (W)
Lockheed Martin
MCS
220/110
0.9
160
Cost
$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 silicon
Power Voltage (Vpm)
30.1 [V]
Maximum Power Current (Ipm)
6.55 A
Maximum 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)
12
Rated capacity (Ah)
100
Specific Energy (Wh/Kg)
66
Specific Power ( W/Kg)
150
Weight (kg)
18.5 (each)
Table 3.5 – Saft NHE Battery Specification
21
3.2 Decision Making Analysis
Throughout 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
Design
for All PEAK Systems
East Africa
Location
Overall Power Generation
Must be renewable and fossil fuel sources
of energy and must meet EPA Standards
EU emissions standards.
110V / 220V and 60
Electricity
Hz
Design 1 & 2: Less
Than 6 kW; Design
Power
3 & 4: Less Than
Consumption
2kW
Less than 5,000 lbs
Total Weight
Packaging / Volume Fits on a 463L Pallet
All components meet
safe operation
Safety
standards
Electrical, Battery or
Power Source
Wasted Heat
Water Purifier
Microorganisms >
Filtered
0.5 microns; Viruses
contaminants
< 0.5 microns
Carbon Filtration
Polishing
Taste, Odor, Organic
compounds and
Remove
bacterium
Electrical
Power Source
370 L water per day
Water Supply
Cooker
Sun or Biomass
Power Supply
Electrical Heating
Secondary Power
Coils
Supply
6 kg of water to
100oC in less than 4
Heating Capacity
hrs
1
2
3
4
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Table 3.6: Decision Matrix on Specification/Constraints
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
22
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)
Alternatives
Requirements
Weight (%)
Design1 Design2 Design3 Design4
Smallest size
10
D
S
Best packaging & transportability:
Lowest weight
15
A
Best durability for environment
10
T
S
Environmental Consideration:
Lowest environmental Impact
10
U
S
Lowest total power consumption
10
M
S
+
+
Consumption Efficiency:
Lowest JP8 consumption
5
S
+
Lowest gathered resources
5
S
Greatest Availability of technology
15
S
S
Greatest reliability and with lowest maintenance
10
S
Lowest cost
10
+
+
+
Total +
0
1
2
3
Total 0
4
7
4
Overall total
0
-3
-5
-1
Weighted total
0
-35
-45
-20
Table 3.7: Pugh Analysis
3.3 Final Design: Overall Schematics of Subsystems and Components
Design 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 Components
In 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
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
23
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
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.
24
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
energy when no solar energy is available. The battery can only be charged by the DC loads of the
solar panels.
25
3.5 Packaging and Installation
The 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
Design 1 Volume Information
Component
Water Purifier
Solar Cooker
1 kW SolarDiesel Power
System
Volume
(m3)
Calculation
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
0.8m x .8m x .25m = 0.25992m3
Volume Total
Size Each (m)
(m3)
1.64* 0.958*0.046
0.636
3 LCPV panel
0.390* 0.195*
10 Battery (SAFT NHE0.164
0.120
MH 12v 100Ah)
TOTAL
Table 3.8: Final Design Volume Information
Weight (kg)
Final Design Component
24.95
Water Purifier
62.87
Solar Cooker
245
Solar Power System
TOTAL
332
Table 3.9: Final Design Total Weight
0.99
0.16
0.79
2.562
Weight (lbs.)
55.01
138.62
539
732.8
27
3.6 Materials and Economic Analysis
3.6.1 Initial Purchase Cost
Design 1
Component
Cost (USD) Vendor
Water Purifier
$2,165.00 Aqua Sun International
Solar Cooker
$870.00 Sun-Ovens International
Solar-Diesel Power System
$18000.50 Zytec LCPV /Saft International
Lockheed Martin
NGC Communication
$16,005.00
System
Total
$37,040.50
Table 3.10: Final Design Initial Purchase Cost
3.6.2 Annual Maintenance Cost
Annual Maintenance Cost
Component
Cost (USD)/Yr
Water Purifier
$410.00
Solar Cooker
$50.00
1 kW Solar Power System
$2500.00
Communication System
$216.00
Total
$3176.00
Table 3.11: Final Design Maintenance Cost
3.7 Safety Analysis of the Final Design
This 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 Purifier
The 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
#
1
Function
UV light
Potential
Failure
Modes
UV light is not
on
4
Purified
water
S
E
V
C
l
s
a
s
Potential
Causes of
Failure
O
C
C
Current
Design
Controls
D
E
T
Stop water
flow
9
No power
6
None
1
Stop water
flow
9
UV bulb
reached
unsafe
condition
3
None
1
Water is dirty
or bad tasting Filter problems
water
8
Filter reached
maximum life
expectancy
3
None
5
Washable/
Reusable PreFilter is
wedged
3
Dirty incoming
2
water
None
1
2
3
Potential
Effects of
Failure
Water flow is
slow
R
P
N
Responsib
Recomme le Person
nd Actions & Target
Date
Actions
Taken
Purifier
wouldn"t
Supply Aux
work until
12 V
Jahirul
54
isupply Aux
electrical Chowdhury
12 V
power
electric
power
Purifier
wouldn"t
Install new
Jahirul
27
work until
UV bulbs Chowdhury
install new
UV bulbs
Don"t use it
Replace all
Jahirul
until
120
the filters Chowdhury reaplce all
the filters
For faster
flow,
Wash/clean
Jahirul
6
washing
the pre-filter Chowdhury
pre-fliter is
required
S O D R
E C E P
V C T N
1
1
1
1
1
1
1
1
2
3
1
6
1
1
1
1
Table 3.12: Water Purification DMFEA
3.7.2 Solar Cooker
The 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
#
Function
Potential
Failure Modes
Potential
Effects of
Failure
C
l
s
a
s
O
Potential Causes of
C
Failure
C
Current
Design
Controls
D R
E P
T N
Recommend Actions
Responsible
Person &
Target Date
Actions Taken
S O D R
E C E P
V C T N
3
Heating Coil Fails
5
None
5 75
Add Thermocouple
Feedback
E. Gingrich
Added Thermocouple
3 5 3 45
Feedback
2
4
Temperature
Controler Fails
5
None
5 100
Add Thermocouple
Feedback
E. Gingrich
Added Thermocouple
4 5 3 60
Feedback
3
5
Dirty Window
10
None
5 250
Clean window
4
9
Not enough Solar or
6
electrical Energy
None
5 270
See power generation
FMEA
None
Add Thermocouple
5 100
Feedback
1 Cook Food
Undercooked
Unsafe Food
Food
S
E
V
5
6
7
Over-done
Food
Bad tasting
food
4
Temperature
Controler Fails
4
Long cooking time
5
4 Food Timmer 2 32
E. Gingrich Incluced Cleaning Kit 5 10 1 50
##
Added Thermocouple
E. Gingrich
4 5 3 60
Feedback
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
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.
#
Function
Potential
Failure
Modes
1
Solar Power
Generation
Limited
Sunlight
2
Panel failed
3
Conroller
Failed
Potential Effects of
Failure
Failed to generate the
required power
Failed to generate the
required power
C
S
l
E
s
a
V
s
3
8
Potential
Causes of
Failure
O
C
C
Dust storm or
cloudy days
4
Piece broke
during installation 2
or transporting
Current Design Controls
Clean the panles. Operation &
1 12
Maintenance instructions
3
Light detector. Operation &
Maintenance instructions
1 27
Light detector and
Operation and
Maintenance
instructions
Waleed AlTaie, Era
Raizada
9 3 1 27
1 27
Light detector and
Operation and
Maintenance
instructions
Waleed AlTaie, Era
Raizada
9 3 1 27
1 27
Light detector and
Operation and
Maintenance
instructions
Waleed AlTaie, Era
Raizada
9 3 1 27
1 27
Check periodically
the electrical
connections for
loose connections
and corrosion.
Waleed AlTaie, Era
Raizada
9 3 1 27
4
3
5
Battrey Failure
Cells
disqualification
3
Light detector. Operation &
Maintenance instructions
3
Check periodically the
electrical connections for
loose connections and
corrosion. Operation &
Maintenance instructions
9
Corrosion
3 4 1 12
8 2 3 48
Light detector. Operation &
Maintenance instructions
Wiring Failure
Waleed AlTaie, Era
Raizada
Waleed AlTaie, Era
Raizada
Device
malfunction
6
Clean the panles
and Operation and
Maintenance
instructions
Operation and
Maintenance
instructions
Failed to changes DC
Inverter Failed voltage to AC from 9
batteries or panels
Failed to run the
system
S O D R
Responsible
Actions
E C E P
Person &
Taken
Target Date
V C T N
3 48
Device
malfunction
9
Recommend
Actions
Operation & Maintenance
instructions
Failed to regulates
the voltage & current
9
coming from panels to
the battery
Failed to obtain the
required power
D R
E P
T N
Table 54: Solar Power System DMFEA
31
3.8 Features & Operations
This 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 amperehours of 100Ah.
32
4. Design Analysis & Verification
4.1 Photovoltaic Power System / Backup Generator Design Analysis
A 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/𝑑𝑎𝑦
𝐴𝑣𝑒𝑟𝑎𝑔𝑒 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 𝐴𝑚𝑝𝑠
𝑂𝑝𝑡𝑖𝑢𝑚 𝐴𝑚𝑝 𝑜𝑓 𝑆𝑜𝑙𝑎𝑟 𝑀𝑜𝑑𝑢𝑙𝑒 𝑈𝑠𝑒𝑑.
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
𝐸𝑠𝑎𝑓𝑒 =
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.
𝑁𝑏𝑎𝑡𝑡𝑒𝑟𝑖𝑒𝑠 =
𝐶𝑎𝑝𝑎𝑐𝑖𝑡𝑦 𝑜𝑓 𝑡ℎ𝑒 𝑏𝑎𝑡𝑡𝑒𝑟𝑦 𝑏𝑎𝑛𝑘
𝑐𝑎𝑝𝑎𝑐𝑖𝑡𝑦 𝑜𝑓 𝑜𝑛𝑒 𝑏𝑎𝑡𝑡𝑒𝑟𝑦
Refer to appendix III & V for design power system technical specifications.
33
4.2 Solar Cooker Design Analysis
The 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.
2.
3.
4.
5.
Establish design criteria that included heating 6kg of water to 100⁰C
Perform a literature review of solar cooker designs
Assume a cooker efficiency based on literature review
Select a location on earth and calculate the average daytime irradiation
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 Calculations
Performance factor
Cook Time (hour)
Water mass (g)
Density of water (kg/m3)
1
4
6000
1000
Heat Capacity Water (J/kg-K)
∆T (K)
Energy Needed (J)
Irradiation Needed (W)
Area Needed (m2)
4186
75
1883700
131
0.581
Figure 4.1: Solar cooker calculations
4.6 Solar Cooker Verification
In 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 Conditions
The 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 Properties
The 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-k
2310
502.48
830
2310
16.27
1.15
Wood 700
Steel 8030
Glass 2220
Table 4.2: Solar cooker material properties
35
4.4.3 Boundary Conditions
The 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 Calculations
After 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. Appendix
5.1 Appendix I: Water Purifier
5.1.1 Minimum UV Light to Destroy Contaminates
Examples 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 Process
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].
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.
 Cupric oxide/ARTI-64: This water treating composition will remove arsenic as As3 and
As5 from water.
38
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.
Segment-B.
US Patent Pub. No.: US 2006/0180550 A1
US Patent Number: 4,849,100 or
Responder A (Aqua Sun International)
\
Figure A.I.1: Water Purification System
Summary of Segment-A
This 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.
Summary of Segment-B
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.
Table A.I.1 – Water Purifier Design Segments Summary
39
5.2 Appendix II: Solar/Wood Cooker
5.2.1 Irradiation Map of Africa (PVGIS, 2008)
Figure A.II.1 – Irradiation Map of Africa
5.2.2 Solar Cooker Efficiency

Energy output mc c pw (Twf  Twi / t

Energy input
I t Asc
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
Fp 
Energy reflected by the reflectors fall on the glass cover
Energy falling on the cover due to direct radiation
The concentration of the cooker will be (Fp +1). (Algifri, 2001)
5.2.4 Solar Cooker Cost
Cost
$40.00
Heating Coil
$100.00
Temperature Controller
$50.00
Glass
$300.00
Reflectors
$300.00
Inner and outbox
$30.00
Insulation material
Fasteners and Miscellaneous $50.00
$870.00
Total
Table A.II.1 – Solar Cooker Cost
40
5.2.5 Solar Cooker Weight
Weight [kg]
3
Heating Coil
2
Temperature Controller
7
Glass
18
Reflectors
30
Inner and outbox
2
Insulation material
1
Fasteners and Miscellaneous
63
Total
Table A.II.2 – Solar Cooker Weight
5.2.6 Solar Cooker Calculation
Performance factor
Cook Time
Water mass
Density of
water
Volume Water
1
4 hrs
14400 s
6000 g
6 kg
1000 kg/m^3
0.006 m3
6L
Heat Capacity Water
∆T
Energy Needed
Power
Needed
Area Needed
4186 J/kg-K
75 K
130.8125 W
0.581388889 m2
Length of each side (if
square)
Heating
Element
Efficiency
0.98
1883700 J
1883.7 kJ
Heating
Element
Needed
533.9285714 W
0.762488616 m
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)
JP-8
0.39
Volumetric Flow
Rate (L/s)
0.0003
Table A.II.4 – Electric Generation Flow Rate – 6kW
41
Electric Generation 2kW
Fuel
Mass Flow
Rate (g/s)
JP-8
0.13
Volumetric Flow
Rate (L/s)
0.0001
Table A.II.5 – Electric Generation Flow Rate – 2kW
5.3 Appendix III: Power Generation
5.3.1 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
𝑊ℎ
𝑊ℎ
𝐴𝐶 𝑤𝑎𝑡𝑡 ℎ𝑜𝑢𝑠 𝑝𝑒𝑟 𝑤𝑒𝑒𝑘 𝑎𝑓𝑡𝑒𝑟 𝑖𝑛𝑣𝑒𝑟𝑡𝑒𝑟 𝑙𝑜𝑠𝑠 = 31, 950 𝑊𝑘 × 1.2 =38,340 𝑤𝑘
3. Amp-Hours in a day
𝐼𝑛𝑣𝑒𝑟𝑡𝑒𝑟 𝐷𝐶 𝐼𝑛𝑝𝑢𝑡 𝑉𝑜𝑙𝑡𝑎𝑔𝑒 = 24𝑉
𝑊ℎ
38,340
𝐻𝑟
𝑑𝑎𝑦 1597.5 𝐴ℎ
𝐴𝑚𝑝 −
𝑢𝑠𝑒𝑑 𝑏𝑦 𝐴𝐶 𝐿𝑜𝑎𝑑𝑠 =
=
𝑤𝑒𝑒𝑘
24𝑉𝐷𝐶
𝑤𝑘
1597.5𝐴ℎ
𝐻𝑜𝑢𝑟
𝐴ℎ
𝑤𝑘
𝐴𝑚𝑝 −
=
= 228.2
𝑑𝑎𝑦
𝑑𝑎𝑦
𝑑𝑎𝑦
7
𝑤𝑘
4. Array Sizing
𝐵𝑎𝑡𝑡𝑒𝑟𝑦 𝐶ℎ𝑎𝑟𝑔𝑒 𝑜𝑟 𝐷𝑖𝑠𝑐ℎ𝑎𝑟𝑔𝑒 𝐶𝑜𝑚𝑝𝑒𝑛𝑠𝑎𝑡𝑖𝑛𝑔 𝐹𝑎𝑐𝑡𝑜𝑟 = 1.2
𝑇ℎ𝑒 𝑙𝑜𝑠𝑠 𝑓𝑟𝑜𝑚 𝑏𝑎𝑡𝑡𝑒𝑟𝑦
𝑐ℎ𝑎𝑟𝑔𝑒
𝐴ℎ
𝐴ℎ
= 228.2
× 1.2 = 273.8
𝑑𝑖𝑠𝑐ℎ𝑎𝑟𝑔𝑒
𝑑𝑎𝑦
𝑑𝑎𝑦
42
𝐴𝑣𝑒𝑟𝑎𝑔𝑒 𝑠𝑢𝑛 ℎ𝑜𝑢𝑠 𝑝𝑒𝑟 𝑑𝑎𝑦 𝑖𝑛 𝐴𝑓𝑟𝑖𝑐𝑎 = 5.56 𝑆𝐻 (19 𝑤𝑖𝑡ℎ 𝐿𝐶𝑃𝑉)
𝑇𝑜𝑡𝑎𝑙 𝑆𝑜𝑙𝑎𝑟 𝐴𝑟𝑟𝑎𝑦 𝐴𝑚𝑝𝑠 =
273.8𝐴ℎ/𝑑𝑎𝑦
= 14.4 𝐴
19 𝑆𝐻
𝑀𝑎𝑥𝑖𝑚𝑢𝑚 𝐴𝑚𝑝𝑠 𝑜𝑓 𝑆𝑜𝑙𝑎𝑟 𝑃𝑎𝑛𝑒𝑙 = 8.65
𝑵𝒖𝒎𝒃𝒆𝒓 𝒐𝒇 𝑺𝒐𝒍𝒂𝒓 𝑷𝒂𝒏𝒆𝒍𝒔 =
𝟏𝟒. 𝟒 𝑨
= 𝟐. 𝟐𝟒 = 𝟑
𝟔. 𝟓𝟓𝑨
5. Battery Sizing
𝐷𝑎𝑖𝑙𝑦 𝐴𝑚𝑝 − 𝐻𝑜𝑢𝑟 𝑅𝑒𝑞𝑢𝑖𝑟𝑚𝑒𝑛𝑡 = 1116.8
𝑁𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝐶𝑜𝑛𝑠𝑒𝑐𝑢𝑡𝑖𝑣𝑒 𝐶𝑙𝑜𝑢𝑑𝑦 𝑊𝑒𝑎𝑡ℎ𝑒𝑟 𝐷𝑎𝑦𝑠 = 1 𝐷𝑎𝑦
𝐴𝑚𝑜𝑢𝑛𝑡 𝑜𝑓 𝑎𝑚𝑝 − ℎ𝑜𝑢𝑟 𝑛𝑒𝑒𝑑 𝑡𝑜 𝑠𝑡𝑜𝑟𝑒 𝑖𝑛 𝑡ℎ𝑒 𝑠𝑦𝑠𝑡𝑒𝑚 = 1116.8 𝐴ℎ × 1 𝐷𝑎𝑦 = 1118.8𝐴ℎ
𝑇ℎ𝑒 𝑠𝑡𝑜𝑟𝑎𝑔𝑒 𝑛𝑒𝑒𝑑𝑒𝑑 𝑏𝑦 𝑡ℎ𝑒 𝑑𝑒𝑝𝑡ℎ 𝑜𝑓 𝑑𝑖𝑠𝑐ℎ𝑎𝑟𝑔𝑒 =
390.88𝐴ℎ
= 781.76𝐴ℎ
0.5
𝑇𝑜𝑡𝑎𝑙 𝐵𝑎𝑡𝑡𝑒𝑟𝑦 𝐶𝑎𝑝𝑎𝑐𝑖𝑡𝑦 = 781.76 𝐴ℎ × 1.04 = 813.0304
𝐵𝑎𝑡𝑡𝑒𝑟𝑦 𝐶ℎ𝑜𝑠𝑒𝑛: 𝑆𝐴𝐹𝑇 𝑁𝐻𝐸 − 𝑀𝐻 12𝑣 100𝐴ℎ
𝑁𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝐵𝑎𝑡𝑡𝑒𝑟𝑖𝑒𝑠 𝑤𝑖𝑟𝑒𝑑 𝑖𝑛 𝑝𝑎𝑟𝑎𝑙𝑙𝑒𝑙 =
813.0304 𝐴ℎ
= 4.13 = 5
100𝐴ℎ
𝑁𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝐵𝑎𝑡𝑡𝑒𝑟𝑖𝑒𝑠 𝑤𝑖𝑟𝑒𝑑 𝑖𝑛 𝑠𝑒𝑟𝑖𝑒𝑠 =
24𝑉
=2
12
𝑵𝒖𝒎𝒃𝒆𝒓 𝒐𝒇 𝑩𝒂𝒕𝒕𝒆𝒓𝒊𝒆𝒔 𝑹𝒆𝒒𝒖𝒊𝒓𝒆𝒅 = 𝟏𝟎
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
1
(𝑑𝑒𝑛𝑠𝑖𝑡𝑦)(𝑆𝑤𝑒𝑝𝑡 𝐴𝑟𝑒𝑎)(𝑃𝑜𝑤𝑒𝑟 𝐶𝑜𝑒𝑓𝑓𝑖𝑐𝑖𝑒𝑛𝑡)(𝑉𝑜𝑙𝑢𝑚𝑒)3
2
𝑃𝑜𝑤𝑒𝑟
⟶ 𝑆𝑤𝑒𝑝𝑡 𝐴𝑟𝑒𝑎 =
0.5 × 𝑑𝑒𝑛𝑠𝑖𝑡𝑦 × 𝑃𝑜𝑤𝑒𝑟 𝐶𝑜𝑒𝑓𝑓𝑖𝑐𝑖𝑒𝑛𝑡 × 𝑉𝑜𝑙𝑢𝑚𝑒 3
𝑃𝑜𝑤𝑒𝑟 =
43
⟶ 𝑆𝑤𝑒𝑝𝑡 𝐴𝑟𝑒𝑎 =
2000
= 31.47𝑚2
𝑘𝑔
0.5 × 1.13 3 × 0.4 × (6.5)3
𝑚
𝜋
𝐴𝑟𝑒𝑎 = 𝐷2
4
4 × 𝑆𝑤𝑒𝑝𝑡 𝐴𝑟𝑒𝑎
⟶ 𝑅𝑜𝑡𝑜𝑟 𝐷𝑖𝑎𝑚𝑒𝑡𝑒𝑟 = √
𝜋
4 × 31.47 𝑚2
√
⟶ 𝑅𝑜𝑡𝑜𝑟 𝐷𝑖𝑎𝑚𝑒𝑡𝑒𝑟 =
𝜋
⟶ 𝑅𝑜𝑡𝑜𝑟 𝐷𝑖𝑎𝑚𝑒𝑡𝑒𝑟 = 6.33 𝑚
5.3.3 Solar-PV System Location Parameters
o Location: W Africa Senegal, Dakar
o Latitude: 14° 38' N
o Longitude: 17° 27' W
o Year Average: 5.56 kWh/m2/day
o Air Density: 1.235 kg/m³
Average Irradiance kWh/m2/day
January
February
March
April
May
December
July
August
September
October
November
June
Year Average
4.63
5.03
5.46
5.13
5.01
5.15
5.7
6.7
6.56
6.56
5.77
4.84
5.56
Table A.III.2 – Solar Power System Parameter
5.3.4 Wind-Power System Location Parameters
44
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)
Solar Panels
Controller
Inverter
Battery
Fossil Fuel
Generator
39
1
1
12
1
2.913
0.028
0.067
0.439
0.324
780
6.4
17.5
900
190.1
28
1
1
48
1
2.024
0.028
0.067
0.439
0.438
Improved
Weight
(kg)
560
6.5
17.5
892.8
120
3.771
1894
2.995
1597
Total
Table A.III.3 – Design 1 Power Generation Packaging
45
b. Economy
Parts
PV modules
Charge Controller
Inverter
Battery
Communication
Previous Design
Qt
Cost ($)
28
$20,757.52
Improved Design
Qt
Cost ($)
3
$18,826.35
1
1
48
1
1
1
10
1
$580.00
$500.00
$24,000.00
$ 16,000.00
Total Cost
$580.00
$500.00
$7200.00
$ 16,000.00
$50,837.52
$37,040.5
Table A.III.4 – Design 1 Power Generation Economy
Design 2 - 3.5 kW Power System
c. Packaging
Previous Design
Parts
Wind
Turbine +
Blades
Generator
Quantity
Volume
(m3)
1
0.368
Blades
0.6162
Improved Design
Net
Weight
(kg)
Upper
Section
Middle
Section
Bottom
Section
Tower
Base
0.286
0.456
0.0154
Controller
1
Battery
Generator
20
1
416
0.008
0.0154
1408
3.405
1
Net
Weight
(kg)
1
0.008
Inverter
Total
1
425
1
Hydraulic
Free
Standing
Tower (12
m)
Quantity
Volume
(m3)
1408
3.405
.0936
1.777E4
0.732
0.324
93
1
70
1
1190
190.0
20
1
5.56
3376
0.0936
1.777E4
0.186
0.197
38.5
4.64
2404.5
50
372
120
Table A.III.5 – Design 2 Power Generation Packaging
46
d. Economy
Parts
Wind Turbine (Charge
Controller included)
Hydraulic Towers
Inverter
Battery
Generator
Previous Design
Qt
Cost ($)
1
$20,000.00
Improved Design
Qt
Cost ($)
1
$10,000.00
1
1
20
1
1
1
20
1
$10,000.00
$3,999.00
$12,000
$7000.00
$10,000.00
$2,999.00
$10,000.00
$5000.00
$52,999.00
Total Cost
$37,999.00
Table A.III.6 – Design 2 Power Generation Economy
e. Power Curve
Figure A.III.2 – Design 2 Power Curve
Design 3 – 2 kW Power System
Packaging
Previous Design
Parts
Wind
Turbine +
Blades
Quantity
Generator
1
Blades
Improved Design
Net
Net
Volume
Volume
Weight
Quantity
Weight
(m3)
(m3)
(kg)
(kg)
0.286
1
0.286
416
416
0.6162
0.456
1
Hydraulic
Free
Standing
Tower (12
m)
Upper
Section
Middle
Section
Bottom
Section
1
0.008
0.0154
3.405
0.008
1408
0.0154
1408
3.405
47
Tower
Base
Inverter
1
Controller
1
Battery
Generator
20
1
.0936
1.777E4
0.732
0.169
5.32
3241
Total
93
1
70
1
1190
64
20
1
0.0936
1.777E4
0.186
0.169
38.5
4.62
2348.5
50
372
64
Table A.III.7 – Design 3 Power Generation Packaging
f. Economy
Parts
Wind Turbine (Charge
Controller included)
Hydraulic Towers
Inverter
Battery
Generator
Previous Design
Qt
Cost ($)
1
$10,000.00
Improved Design
Qt
Cost ($)
1
$10,000.00
1
1
20
1
1
1
20
1
$10,000.00
$1,999.00
$12,000
$1800.00
$35,7999.00
Total Cost
$10,000.00
$2,999.00
$10,000.00
$1800.00
$34,799.00
Table A.III.8 – Design 3 Power Generation Economy
g. Power Curve
Figure A.III.3 – Design 3 Power Curve
Design 4 - 2 kW Power System
48
h. Packaging
Previous Design
Improved Design
Parts
Qt
Volume
(m3)
Net Weight
(kg)
Qt
Volume
(m3)
Solar Panels
Controller
Inverter
Battery
Fossil Fuel
Generator
13
1
1
4
1
0.971
0.028
0.067
0.146
0.169
260
6.4
17.5
300
64
17
1
1
28
1
2.024
0.028
0.067
0.439
0.169
Improved
Weight
(kg)
340
6.4
17.5
520.8
64
1.381
647.9
1.748
948.7
Total
Table A.III.9 – Design 4 Power Generation Packaging
i. Economy
Parts
PV modules
Charge Controller
Inverter
Battery
Fossil Fuel Generator
Total Cost
Previous Design
Qt
Cost ($)
13
$7,275.45
1
1
4
1
$580.00
$500.00
$2,400.00
$1800.00
Improved Design
Qt
Cost ($)
17
$12,602.78
1
1
28
1
$12,555.45
$580.00
$500.00
$14,000.00
$ 1800.00
$29,482.78
Table A.III.10 – Design 4 Power Generation Economy
5.5 Appendix V: Technical and Environmental Analysis (Design 1)
5.5.1 Thermal-Fluid Specifications
5.1.1.1.1 Water Purifier Maintenance
The 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).
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.
Note: The more maintenance information and costs can be found in Table 33.
49
5.5.1.2 Solar Cooker
It was assumed that the average solar radiation in the horizontal plane was 450W/m 2. 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
120⁰C. Based on energy calculations it was found that 0.6m2 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 45⁰ with respect to the horizontal.
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 Maintenance
Solar 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.
Note: The more maintenance information and costs can be found in Table 33.
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.
50
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 Maintenance
The 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.
Note: The more maintenance information and costs can be found in Table 33.
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.
51
5.5.2.2 Solar Cooker
Solar 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 Generation
Solar/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 Plan
There 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 Newletter
2. Develop and provide speakers on the Relief Kit to military and companies that are
interested in humanitarian relief
3. Develop and maintain a Relief Kit webpage
4. Prepare press releases
5. Conduct a trade show that would allow companies to showcase their humanitarian relief
products
52
5.7 Appendix VI: Complete Maintenance Information and Costs
COMPLETE MAINTENANCE INFORMATION
WATER PURIFIER
DESCRIPTION
SEGMENT A
Zeolite & Cupric Oxide/ARTI-64:
Remove arsenics and heavy metal
LIFE EXPECTANCY
APPROXIMATE LIFE
EXPECTANCY depends on
how dirty incoming water is
or 5,000 gallon or 6 month
maximum.
SEGMENT B
WASHABLE / REUSABLE PreFILTER:
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.
SEDIMENT FILTER:
Removes ground water sediment and
protects the carbon block filter from
premature clogging. Not washable.
HVAC AND TENT
Solar-Diesel Power System O&M
3.5 kW solar-Diesel Power System Maintenance Cost
Maintenance
Annual
Cost
Solar Power: Module array cleaning, dc-electrical check (controller and
$2,000.00
batteries), inverter & main distribution board preventive maintenance,
and energy production analysis & reporting.
Diesel Generator:preventive maintenance consists of general inspection,
lubrication service, cooling system service, fuel system service, and
regular engine exercise.
Total
Annual
$500.00
Maintenance
Annual
Cost
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
Interval
30 Days
Cost
17.97
Adjust Tent Guide
Cables
Daily
0
$2,500.00
2 kW Solar-Diesel Power System O&M Cost
APPROXIMATE FILTER
LIFE EXPECTANCY
depends on how dirty
incoming water is or 1 year
maximum
Solar Cooker
Maintenance Task
Change HVAC Filter
Total
Annual
Make sure tent stakes are
Daily
0
secure
General Inspection (look
Daily
0
for holes, rips, tears,
debris)
Total Maintenance Cost: $18.00/month
Absorption System: Chillii PSC12 Kit with Wood Boiler
Maintenance
Description
Time Interval
Tools needed for
maintenance
The oven window
will need to be
cleaned.
After each use. Less
than five minutes of
cleaning will be
required before use.
A standard window
cleaner will be used.
The oven’s heating element will be designed robustly enough to last the
lifetime of the product.
Solar Cooker Total Maintenance cost:
$50 per year
$1,420.00
APPROXIMATE FILTER
LIFE EXPECTANCY
depends on how dirty
incoming water is or 1 year
maximum.
0.5 micron CARBON BLOCK with
CYSTS AND VOC’S REDUCTION:
*Diesel Generator:preventive maintenance consists of general
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 APPROXIMATE UV BULB
LIFE EXPECTANCY 8000
added to drinking water. The ultraviolet
hours, or approx 12 – 18
range is ideal for killing Micro-organisms
months.
such as E-coli, Coli form, Cholera,
Legionnaires Disease, Hepatitis Virus,
Typhoid Fever, Dysentery, Infectious
Jaundice,
Influenza, Enteric Fever and many other
unwanted Microorganisms.
Total Maintenance Cost: Approximately, $410.00 per year
Maintenance Task and Interval
Cost
Wood Cooker
Wind-Diesel Power System O&M
Maintenance
Description
3.5 kW Wind-Diesel Power System O&M Cost
Maintenance
Removes and reduces giardia lamblia and
cryptosporidium cysts, volatile organic
APPROXIMATE FILTER
chemicals "VOC's" pesticides and
LIFE EXPECTANCY 10,000
herbicides, turbidity reduction, sediment,
gallons / 37,000 liters or one
color, bad taste and odors such as hydrogen
year of clean incoming water
sulfide "rotten egg smell" and many other
maximum.
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 FDAcompliant materials.
$220.00
inspection, lubrication service, cooling system service, fuel system
service, and regular engine exercise.
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.
Annual
Cost
Total
Annual
O&M Cost
$2,400.00
The entire stove and chimney inside
the wood boiler will need to be cleaned The cost will vary
thoroughly every month. A small
according to different
shovel included with the stove will be brands of cleaning
used to remove the ash out of the
supplies used. An
combustion chamber. The use of a
estimated cost would
solvent may be necessary for the
be roughly 20 USD.
chimney.
$2,900.00
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
Maintenance
Annual
Cost
Wind Power
$2,400.00
*Diesel Generator: Same as above.
$150.00
Total
Annual
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.
Time Interval
Tools needed for
maintenance
The wood stove will
need to be cleaned of
ash after each use.
A small shovel included
After about a month
with the stove will be
of use a more
After each use. Every used to remove the ash
thorough cleaning of
month clean the
out of the combustion
the oven will be
chimney.
chamber. The use of a
required. The walls
solvent may be necessary
and chimney will
for the chimney.
need to be scraped of
any build up.
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.
Other components of the wood stove will be designed to last for the
lifetime of the product.
Wood Cooker Total Maintenance cost:
$150 per year
$2,550.00
Total Maintenance Cost: Approximately, $20/year
53
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Dounis, A.I. and Manolaskis, D.E., (2001), “Design of a Fuzzy System for Living Space
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