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Design Project 2
TABLE OF CONTENTS: Problem Statement---------------------------------------------------------------------------------1 Executive Summary--------------------------------------------------------------------------------2 Design Approach-----------------------------------------------------------------------------------4 Design Approach 1: Hydronic System-------------------------------------------------6 Design Approach 2: Electrical Heating System--------------------------------------11 Economic Analysis--------------------------------------------------------------------------------14 Operability, Health and Safety and Manufacturability---------------------------------------19 Conclusions-------------------------------------------------------------------------XXXXXXXXX
PROBLEM STATEMENT
NFL football stadiums operating in northern climates have problems with the field surface freezing in the winter, when conditions of extended freezing can occur. In addition to making the surface difficult to play on, extended periods of freezing can kill the grass, making the playing surface even worse. In order to prevent this, several NFL stadiums have installed subterranean heating systems to keep the surface temperature above freezing during the winter months and extend the grass growing season. The systems can also alleviate snow build up (but not totally prevent it) on the field during games if snow occurs during a game. The objective of this project is to design two different kinds of field heating systems that will be able to prevent ground freezing during the winter months and will be able to help alleviate snow build up during games. The system will operate in Green Bay, WI. Weather data from Green Bay should be used in the design of the system.
Design Data Location: Green Bay, WI Surface: Grass Desired surface temperature: 40-45 degrees Desired root zone temperature: 75-80 degrees Operating Life: 20 years
Figure 1: Football field dimensions Important considerations: Root zone is the lower half of the sand layer which, in this case, has been considered to be 6-10 inches below the surface. The system has to be designed for the most extreme conditions. However, much of the time, the conditions will be less severe, and the system will not be operating at full capacity. This is the purpose of the temperature sensor/feedback control system. It will adjust the system to the given conditions.
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EXECUTIVE SUMMARY:
The two propositions for keeping the football surface in playing conditions during severely cold and snowy conditions are underground hydronic heating system and electrical heating system. These systems can prevent the grass from dying from cold as well as provide enough heat at the root zone of the grass to allow it to grow well. Hydronic system uses four pumps and four boilers to heat the working fluid (water) and recirculate it through the piping. A piping system has been laid out under the root zone in order to provide the required heat to keep the root zone temperature at 75 F and surface temperature at 40 F. Each piping system has a header that distributes hot water into the field in small diameter pipes. These pipes lose heat energy to the field and the cold water is collected by another large pipe which carries it to the pump and eventually to the boiler. The function of the pump is to make up for the pressure drop in the pipes and recirculate the fluid. A brief summary of hydronic system is given below: TABLE 1: Summary for the Hydronic system design Number of Zones Size of Zones Heat Provided by Boiler Number of Boilers Number of Pumps Mass Flow Rate of Water Temperature of Water Pipe Sizes Pipe Material Depth of Pipes Loop Length Number of Loops Material Cost Operation Cost (5 Months) Operation Cost (12 Months) 4 13,500 ft2 992,000 Btu/hr 4 4 107 gpm 200 F 1/2 Sch 40 and 4 Sch 40 PVC 30.54 inches 150 ft 120 $159,751.4 $436,838.06 $1,050,811.54
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The electrical heating system uses Sun-touch Promelt heatig mats in order to provide the heat energy required to maintain the desired root zone and the surface temperature. The design has been based on extreme weather conditions and therefore, a feedback control system has been installed in order to control the heat supplied at times when the conditions are not as severe. There are eight zones which can be individually controlled. Each zone uses 66 2ft x 30 ft Promelt heating mats resulting in a total of 528 mats. The mats are placed with a spacing of 17.7 inches. The wiring is done in parallel so that malfunction to one network does not hinder the performance of another. Mats installed at a depth of 7.14 inches below the root zone provide the desired temperatures in extreme weather conditions. A brief summary of hydronic system is given below: TABLE 2: Summary for the Electric heating system design Number of Zones Size of Zones Number of Mats Size of Mats Power of Mats Temperature of Mats Depth of Mats Material Cost Operation Cost (5 Months) Operation Cost (12 Months) 8 6750 ft2 528 2 x 30 ft 38 W 100 F 17.14 inches $375,821.2 $438149 $1051559
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DESIGN APPROACH:
The project required every group to come up with two design approaches. The two means of heating the field our group came up with were electrical heating system using electrical mats and a hydronic system using pumps and boilers. Both the design approaches have been aimed at worst possible weather scenario based on the weather data obtained for the Green Bay, WI area. Most of the parameters that are vital to the calculation of required heating loads are common to both the designs. However, the concepts regarding how the heat is actually supplied to the surface in the desired manner (evenly throughout the field, and in appropriate quantity) is different for the two cases. Our priority is to keep the grass alive in inclement weather conditions and therefore, we focus first and foremost on the root zone temperature and base our design on that. The design root zone depth is 10 in to allow more space for the grass roots. Also, the given requirements of temperature are met only if the soil with correct thermal properties is used. Therefore, saturated sand should be used in the field because it has a thermal conductivity in the range of 1.16 to 2.31 Btu/hrft. The first step is to determine the heat load. Heat load is basically the amount of heat lost from the field surface. Under no losses (that every pipe has been perfectly insulated and there is no loss of heat and all the heat input is being used to heat the root zone soil), and operating under steady state, the system would have to provide this amount of heat to the surface in order to maintain the temperature of the surface. Neglecting radiation, the major source of heat loss from the surface in the extreme case is by forced convection from the cold wind blowing across the field. It is acceptable to neglect the heat loss due to radiation because it does not result in substantial amount of heat loss at such low temperatures and freezing conditions. The convection co-efficient as well as the heat load was calculated using the tabulated values of the wind speeds for Green bay climate and the air properties at the air temperature provided in the weather tables. The value of heat load per square feet was calculated to be 73.45 Btu/hr. These quantities are applicable to both the designs. Antifreezes (chemical compounds) have been added to water to reduce the freezing point of the mixture below the lowest temperature that the system is likely to encounter. Disadvantages to using antifreeze are that it causes breakdown of the system over time, accelerated corrosion of boilers and other system components and reduces efficiency of the system.
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In areas with cold winters, Expanded Polystyrene panels are used to insulate under slabs and the perimeter of foundations. Because EPS is available in a variety of different densities with different compression strengths, the material can accommodate any design load requirements from a residential basement to an industrial warehouse floor with concentrated loads. A typical application would be a floor with hydronic heating where insulating below the heat system is critical to its economical operation. An insulation of Styrofoam 2 inch thick is used 2 inches below the piping and the electric pads, as well as on the sides to force the heat lost from the pipes to flow in upward direction and insure no heat losses.
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The team decided to divide the field into four zones so that heat input into each of four zones could be controlled individually. Each zone has a boiler to heat the cold water coming out of the piping network after losing heat to the field. A pump has been installed in order to recirculate the same fluid. Given below is a figure of piping network for one zone.
Figure 3: Hydronic system piping layout for one out of four zones
FIGURE 4 given below shows a 3D orientation of hot water pipe, cold water pipe and approximate boiler and pump location.
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Figure 4a and 4b: Different views of the hydronic system (a pump, a boiler and one piping loop)
The piping layout is basically a group of loops placed next to each other in parallel. There is one 4 diameter hot water pipe (header), running through the length of one zone (parallel to length of the field), out of which 30 different smaller diameter pipes branch out at every 6 feet distance. Carrying hot water from the boiler, this 4 pipe releases hot water into thirty 1/2 diameter pipes which run into the center of the field and make a U-turn back to the sides of the field (one out of those 30 loops has been shown in the figure above). When these 30 pipes return back on the side of the field, cold water in them is recollected into a 4 diameter cold water pipe.
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This cold water pipe, just like the hot water 4 diameter pipe, runs parallel to the length of the field for every zone. Another 4 diameter pipes starts at the boiler and carries hot water to hot water pipe. This pipe is insulated with Styrofoam wrapped around it to minimize the heat loss. Another 4 pipe connects to the cold water pipe and circulates that water back to the pump. The pump and the boiler can be installed in a mechanical room under the stands, about 75 ft away from the actual playing surface. Also, the piping has been laid out about 20 inches below the root zone temperature in order to make sure that the heat lost from the pipes distributes evenly in all directions and by the time it reaches the root zone area, it has distributed throughout in all directions, although in reality, it is not possible. The temperature distribution in real life situation will fluctuate with highest temperature right above the pipe and lowest at the point between the two pipes. Since the temperature of the surrounding is very low, freezing of water is a possibility which we would like to avoid. Therefore, antifreeze chemicals have been added to water in order to prevent freezing.
Formulae used for calculation: A boiler was first chosen which could provide an acceptable temperature difference between inlet and exit for a given volume flow rate for each zone. After that, the piping network was designed using the software PIP-FLO software in order to calculate the head loss for the whole system. Various 90 degree elbows, tank entrant, as well as branch through were also incorporated while performing the calculations. It was realized that PIP-FLO uses Darcyweisbach equation to solve the piping networks. The software provided us with a pressure drop as well as the required head across the pump for a constant speed pump. The NPSHa was calculated in order to make sure that NPSHr for the selected pump was less that NPSHa available. The thermal properties of water were calculated at the average of the inlet and exit temperature. Convection co-efficient for the hot water running through the pipes was calculated using the following equation,
Rearranging, we get,
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Where, h is the convective heat transfer coefficient, Re is the Reynolds number, Pr is the Prandtl number, Kf is the thermal conductivity of water, and D is the inside diameter of the tube. The temperature drop of the water between entrance of the piping layout and the exit was calculated using the following equation, Where, Q is the total heat transfer rate, which is the heat load, is the mass flow rate of water and CP is the specific heat of the water. Knowing heat load (Q), depth of root zone (L), surface area of the field (A), root zone temperature and the field surface temperature, the equation given below is used in order to find the appropriate thermal conductivity value of the soil. ( )
Surface temperature of the pipe is vital to determining how deep below the root zone the piping must be laid out in order to achieve the desired root zone temperature. The surface temperature of the pipe was calculated using the following equation, [ ]
Where, ODp is the outer pipe diameter, IDp is the inner pipe diameter, Q is the heat load, h is the convective heat transfer coefficient, and L is the length of the pipe. Once the temperature of the outer pipe surface is calculated, the depth of the pipe below the root zone can also be calculated using the following equation, ( )
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Unlike in hydronic system, the heat transfer here takes place only due to conduction (no convection). Each zone has three rows of heating pads installed. Twenty two 2ft x 30 ft pads are installed in every row at spacing of about 17.7 inches. There are 66 pads in one zone and 528
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pads in total. Running at full capacity, the 37 Watt heating pads can reach temperatures of 300 F. However, for this case, the temperature feedback sensor control system has been installed in order to maintain the surface temperature of the pads at 100 F.
The wiring will be done in parallel so that if one of the terminals malfunctions, or needs to be repaired, the others will still run fine. Figure 6 provided above is a top view of one out of eight zones. This outlines how the components and the wiring are divided into different parts. The way the mats will be laid out, there is a terminal box for each of the couple of rows of mats which are connected to a field side junction box. Each of four zones has one of these field side junction boxes enabling one to control the temperature at each zone individually. The two junction boxes are further connected to a main control panel. Figure below shows the side view of the system which further explains the positioning of the components. There is insulation (Styrofoam) inside the ground on top of which the pads have been placed. There is spacing of 7.14 inches between the root zone and the pads in order to provide the desired root zone
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temperature. Finally, the grass is on the top. The thickness of the insulation, which has been placed under the field and on the sides to prevent heat loss, is 2 inches.
Formula used for calculation: The appropriate pads were first chosen based on the heat load for the field and the heating density provided by the pads. Then based on the temperature of the pads and the heat load for steady state heat conduction, the depth of the placement of the heating pads were calculated using the Fouriers conduction law given below,
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Pump Systems, LLC AURORA End Suction Centrifugal Pump 344ABF 2x2.5x7A $1,691 4 $6,764
$12,231.84
$3.04 - Tee-branches Quantity 240 - 90 Elbows 240 - Tee-branches Total Cost Insulation Company Material Price Quantity Total Cost Universal Foam Products Foam sheets 75x45 $3,499.03 16 $55,984.48 $770.64
Grand Total
$159,751.4
Hydronic Design Operation Costs After the installation of the system has been completed the cost to operate and maintain the boilers and pumps must still be taken into account. Pumps We are using 1 HP motors to run the pumps. 1 HP = 0.746 kW With 4 pumps in the system Total Power of pumps = 2.984 kW Boilers The boilers in the system have a 300 kW rating With 4 boilers in the system Total Power of the boilers = 1200 kW Cost Using the electric rate, found from the US energy information administration, for commercial operations: 10.11 cents/kWhr Take operating time in hours multiplied by the total power of the pumps or boilers. Time * Power = kWhr
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To get the cost, multiply the kWhr with the rate from the electric company kWhr * cents/kWhr = cents Dollars = cents/100
Operation Cost for Different Operating Periods Operation Time 3 Months 5 Months 8 Months 12 Months Pump Cost $651.634 $1086.06 $1737.69 $2606.54 Boiler Cost $262,051.2 $436,752 $698,803.2 $1,048,205 Total Cost $262,702.8 $436,838.06 $700,540.82 $1,050,811.54
Company
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Type Model Price Quantity Total Cost Wires Company Model Price Quantity Total Cost Main Power Supply Company Price Quantity Total Cost Contactor Panels Company Model Price Quantity Total Cost
Grand Total
$375,821.20
Electric Design Operation Costs After the installation of the system has been completed the cost to operate and maintain the heating mats must still be taken into account.
Mats We are using 38W mats, with a total of 528 mats in the system. Total Power of mats = 20,064 W = 20.064 kW
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Cost Using the electric rate, found from the US energy information administration, for commercial operations: 10.11 cents/kWhr Take operating time in hours multiplied by the total power of the mats. Time * Power = kWhr To get the cost, multiply the kWhr with the rate from the electric company kWhr * cents/kWhr = cents Dollars = cents/100 Operation Cost for Different Operating Periods Operation Time 3 Months 5 Months 8 Months 12 Months Mats Cost $262,889 $438,149 $701,039 $1,051,559
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Operability:
Both the hydronic system and electric heating system are widely used methods of heating houses, buildings as well as fields and playing surfaces. Both these designs work just like any other thermal system where there is a main control room and the feedback from the sensors is used to increase or decrease the power supply based on the desired conditions. The hydronic system requires lowering or increasing of mass flow rate through the boiler in order to increase or decrease the heat supply. This can be easily done from the control room using control valves. Also, the boiler used in this case has a feature where the temperature of the heated water can be controlled. For the electrical heating system, thermostats are used to restrain the soil temperatures at the operation zones so that the desired temperature is maintained. A control room with electric switches is best for this purpose and can be operated by moderately skilled individual.
Manufacturability:
As mentioned earlier, all the parts used in this design project are standard and hence, there is no need for custom manufacturing any parts. Different components only need to be installed as designed to achieve the operating conditions. Listed below are some key maintenance checks:
Hydronic System 1. Ensure proper operating pressure 2. System should not be flushed unless pressure is too low. Adding new water to the system will contribute to corrosion by introducing oxygen to the fluid.
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3. Pressure test the system to check for leaks (Not all leaks will be visible) 4. Listen to pump for excessive noise. Pump is water lubricated and should be maintenance free. Ensure pump is not leaking, flow capacity, gaskets and seals, check impeller wear, heat coming off of pump, speed of operation, and power consumption. 5. Check boiler for leaks, excessive banging, water level, test low water cutoff switch, visually check combustion chamber, ensure flame stays in fire box, check pressure and temperature of boiler, check pressure and temperature of feed water, open chamber and inspect for scaling. 6. Clean filters
Electric System 1. Check power to control panel. 2. Check power to transformer. 3. Monitor voltage drop across each pad from terminal boxes. (Check for shorts) 4. Ensure control box and transformers stay moisture free. 5. Place ice on snow sensors to ensure thermostat operability. 6. Monitor power consumption of each zone.
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APPENDIX
Calculations:
Hydronic System:
Total Heat Load: Total area of the field (A): 360ft x 150ft = 54000ft2 Ambient wind temperature (T) = -13F Field surface temperature (Ts) = 40F Film temperature (Tfilm): [40 + (-13)] / 2 = 13.5 F Wind speed (extreme condition) (v): 8 Knots= 48609ft/hr Properties of air @ film temperature: Prandtl Number (Pr) = .72219 Kinematic Viscosity () = .48197 ft2/hr Thermal Conductivity (Kf ) = .013457 Btu/hr ft F Reynolds Number, Re = vL/ = [(48609)*(360)] / 0.48197 = 36307737 (turbulent) Nusselt Number, NuL = hL/Kf = 0.037 Re.8Pr1/3 = 37075.32 Therefore, h = NuLKf / L= [37075.32 x 0.013457] / 360 = 1.3858 Btu/ hr ft2F Then, the total heat load, Q, for the field =T/Rth =[40 (-13)]/[1/hA] = 3966434 Btu/hr The total heat head load per ft2 = 3966434/54000 = 73.452Btu/hr Soil thermal conductivity selection: Root zone temperature (TR) = 75F Field surface temperature, (Ts) = 40F Root zone depth (L) = 10 in = 0.833ft Thermal Conductivity (K) = QL/A x (TR Ts ) = [3966434 x 0.833]/54000*(75-40) = 1.7488 Btu/ hr ft F Piping Layout Number of zones = 4 Number of piping loops in one zone = 30 Heat load for one loop zone = 33053.62 Btu/hr Available mass flow rate for the boiler @ 200F for one zone = 106.6 GPM = 53014.97 lbm/hr So, for one loop zone, average available mass flow rate = 1767.166 lbm/hr = 28.502 ft3/hr Temperature drop based on the heat load for one loop,
T = Q/mCp = 33053.62/(1767.166 x 0.971) = 19.26F Pipe selection: in nominal diameter sch 40 PVC Thermal Conductivity of pipe = 0.2025Btu/hr ft F ID = .05183ft OD = .07ft Flow area = 0.00211 ft2 Surface Area = DL = (.05183) (150) = 24.4243ft2 Velocity, V = Q/A = 28.502/.00211 = 13509.31 ft/hr = 3.75ft/sec Inlet temperature, Ti = 200F Exit temperature, Te = 200 - T = 200 - 19.26 = 180.73F Average temperature of water= [200 + 180.73]/2 = 190.36F Properties of water at average temperature, 190.36 F Density, () = 60.299 lbm/ft3 Kinematic Viscosity, () = .01261 ft2/hr Prandtl Number (Pr) = 1.8971 Specific heat (Cp) = .97274 Btu/hr ft F Thermal Conductivity (Kf) = .39025 Btu/hr ft F Reynolds Number (ReD) = VD/ = [13509 x 0.05183] / 0.01261 = 55526.39 Nusselt Number, NuD = hD/Kf = 0.023Re4/5Pr0.3 = 174.0822 So, convection heat transfer coefficient, h = NuD x Kf/ D= 1310.739 Btu/hr ft2 F Outside surface temperature of the pipe using thermal circuit Ts = 200 33053(1/1310.73 x 24.42 + Ln (.07/.05183)/ 2 x 0.2025 x 150) Placement of pipes under root zone: L = (Tpipe TR) x Ksoil/ Q = (147- 75) x 1.7488/73.45 = 1.712ft = 20.54in Pipes must be laid out 20.54 inches below the root zone. Pump selection using PIP-FLO Total pressure drop = 100-93= 7psi Head across the pump = P/ = 7 x 144/62 = 16.25ft NPSHr = Ptank/ + Z hL Pv/ = 100 x 144/62 + 0 16.25 9.33 x 144/62 = 194ft
References
1. Cengel, Yunus A. Heat transfer An Engineering Approach 2nd edition. New York: McGraw-Hill. 2002. 2. Sonntag, R.E. Borgnakke C. and Van Wylen, Fundamentals of Engineering Thermodynamics 3. Janna, William S. Design of Fluid Thermal Systems. Appendix Tables Ed. 3. pp 601-615. 4. Lecture Notes. 5. www.univfoam.com/pricing 6. www.usplastic.com 7. www.hukseflux.com/thermalscience/thermalconductivity.html 8. www.reimersinc.com 9. Pump Systems, LLC 10. www.aurorapump.com 11. http://inditherm.com/default.asp?ContentID=40 12. http://www.suntouch.com/promelt/mats/ 13. http://www.wattsradiant.com/products/promelt/www.e-comfortusa.com 14. www.360flooring.com 15. www.grainger.com 16. www.dynamiccontrolsystems.com