ocaes energy recover system final report_12-05-2016

MAE 586 PROJECT WORK IN MECHANICAL ENGINEERING

DESIGN OF AN ENERGY RECOVERY SYSTEM FOR AN OCEAN COMPRESSED

AIR ENERGY STORAGE SYSTEM TECHNOLOGY DEMONSTRATOR

KEMIT FINCH

ADVISOR: ANDRE MAZZOLENI

DECEMBER 5, 2016

of 84

TABLE OF CONTENTS

1. SCOPE ................................................................................................................................ 4

2. GENERATOR REQUIREMENTS AND SELECTION ................................................................. 4

3. TURBOCHARGER REQUIREMENTS AND SELECTION ......................................................... 6

3.1. TURBOCHARGER REQUIREMENTS ....................................................................................... 6

3.2. TURBOCHARGER PERFORMANCE ........................................................................................ 6

3.3. TURBOCHARGER SELECTION ............................................................................................... 7

4. REDUCTION GEARING REQUIREMENTS AND SELECTION ................................................. 9

5. SUBSYSTEM DESIGN ........................................................................................................ 11

5.1. MECHANICAL COUPLING ................................................................................................... 11

5.2. TURBOCHARGER MODIFICATION ...................................................................................... 13

5.3. TURBOCHARGER LUBRICATION ......................................................................................... 14

6. INSTRUMENTATION AND CONTROL ................................................................................ 19

7. FINAL SPECIFICATION AND OPERATING PARAMETERS ................................................... 21

9. REFERENCES .................................................................................................................... 23

APPENDIX A REQUIREMENTS AND COMPLIANCE MATRICES ....................................................... 24

APPENDIX B ENERGY RECOVERY SYSTEM COMPONENT DATA SHEETS ........................................ 30

APPENDIX C TURBOCHARGER OIL SYSTEM COMPONENT DATA SHEETS ...................................... 41

APPENDIX D INSTRUMENTATION DATA SHEETS ............................................................................ 51

APPENDIX E OCAES ENERGY RECOVERY SYSTEM INTERIM REPORT ............................................. 59

MAE586 OCAES ENERGY RECOVERY SYSTEM FINAL REPORT

Page 2 of 84

LIST OF FIGURES

Figure 1: Heinzmann PGS100 PM Synchronous Generator .......................................................................... 5

Figure 2: Heinzmann PGS100 Generator Self-Cooled Performance ............................................................. 5

Figure 3: Heinzmann PGS100 Generator Forced Cooling Performance ........................................................ 6

Figure 4: Honeywell Garrett GT2052 ............................................................................................................ 8

Figure 5: Power and Torque for GT2052 Turbocharger ................................................................................. 8

Figure 6: Generalized Operating Time for Planetary Reducer .................................................................... 10

Figure 7: Cycle Time of OCAES Energy Recovery System ............................................................................ 10

Figure 8: Anaheim Automation GPBN-0401 Planetary Reducer ................................................................. 11

Figure 9: Adapter Coupling Concept ........................................................................................................... 12

Figure 10: Spider Coupling .......................................................................................................................... 12

Figure 11: Turbocharger Modification ........................................................................................................ 13

Figure 12: Turbocharger Lubrication System .............................................................................................. 14

Figure 13: Oberdorfer S4000L Gear Pump .................................................................................................. 15

Figure 14: Lubrication System Electrical Schematic .................................................................................... 17

Figure 15: 3 Phase Rectifier and DC-DC Converter ..................................................................................... 18

Figure 16: Charge Controller and Battery ................................................................................................... 18

Figure 17: System Instrumentation ............................................................................................................. 20

Figure 18: OCAES Energy Recovery System ................................................................................................. 22

LIST OF TABLES

Table 1: Generator Specification ................................................................................................................... 4

Table 2: Operating Conditions and Physical Constants ................................................................................. 7

Table 3: GT2052 Thermodynamic Analysis Results ....................................................................................... 8

Table 4: Inlet Air Pressure Drop (πt = 1.25, m = 0.07 kg/s) ............................................................................ 9

Table 5: Energy Recovery System Cycle Time .............................................................................................. 10

Table 6: Anaheim Automation Planetary Reducer Specification ................................................................ 11

Table 7: KTR Spider Coupling Specification ................................................................................................. 12

Table 8: Oberdorfer Gear Pump Specification ............................................................................................ 15

Table 9: Properties of Automotive Engine Lubricating Oils ........................................................................ 16

Table 10: Lubricating Oil Heat Removal ...................................................................................................... 16

Table 11: Earl's Performance Oil Cooler Specification ................................................................................ 16

Table 12: Electrical System Component Specification ................................................................................ 18

Table 13: Instrumentation Requirements ................................................................................................... 19

Table 14: OCAES Energy Recovery System Bill of Material.......................................................................... 21

Table 15: OCAES Energy Recovery System Operational Parameters ........................................................... 22

Table 16: Generator Requirements and Compliance Matrix....................................................................... 25

Table 17: Planetary Gear Reducer Requirements and Compliance Matrix ................................................. 26

Table 18: Turbocharger Requirements and Compliance Matrix ................................................................. 27

Table 19: Lubrication System Requirements and Compliance Matrix ........................................................ 28


Page 3 of 84

ENGINEERING UNITS

PARAMETER NOTATION

Length ft /m

Mass kg

Density kg/m3

Pressure m-H2O / psi / kPa

Temperature K / °C / °F

Power hp / kW / kVA

Velocity ft/s / m/s

Angular Velocity RPM

Volumetric Flow Rate gpm

Mass Flow Rate kg/s

Voltage V

Current A

Frequency Hz


Page 4 of 84

1. SCOPE This report follows and completes the design work initiated on an Energy Recovery System for an Ocean Compressed Air Energy Storage technology demonstrator as documented in the interim report on this system (see reference [3] and Appendix E). Together, this final report and the interim report comprise the complete design for the energy recovery system: the system and component requirements, performance analyses, and component specifications. The final specification and operating parameters for the system are summarized in section 7 herein. This report continues the open design tasks that were highlighted at the end of the interim report:

Performance matching of the energy recovery system components

Component selection

Mechanical coupling and turbocharging modification

Turbocharger lubrication

Instrumentation and control

Final specification The OCAES energy recovery system is assembled from existing components for the turbine, reduction gearing and generator, and each has its own operating, performance and interface constraints. As a result, the specification of components is a dynamic and iterative process of finding the best match among the available options. The principle design parameter which constrains the selection of the turbocharger, reduction gearing, and generator is the shaft speed at the design condition. The turbocharger must drive the generator at its rated speed through the planetary reducer. The reducer has limits on acceptable maximum input speeds from the turbocharger; thus the turbocharger shaft speed, and by extension the pressure ratio, are constrained so as to operate within the limits of the planetary reducer. In addition the planetary reducer must be available with an appropriate gear ratio and torque rating to drive the generator at its rated speed.

2. GENERATOR REQUIREMENTS AND SELECTION There are a variety of technologies available for electrical power generation utilizing a rotating magnetic field. A permanent magnet synchronous generator used for small scale wind power is selected because the permanent magnet provides the coil excitation. In addition, small scale wind generators are likely to be provisioned with a keyed shaft which facilitates coupling the generator to the planetary reducer. One caveat is that the required input torque for a number of small scale wind generators runs close to the rated torque for high speed reduction gear trains. Consequently the torque rating of the reduction gearing constrains the generator input torque and therefore the possible generator solutions for the system. The generator requirements as derived from the system level functional, performance, reliability and environmental requirements are defined in Table 16 found in Appendix A. For this system a PM synchronous generator manufactured by Heinzmann is selected. The chosen model is the PGS100, which produces up to 1.8 kVA of 3 phase power at 102 – 105 VAC. This generator’s compliance to the requirements is also shown in Table 16. This generator has performance curves defined for self-cooled and forced cooling operation, shown in Figure 2 and Figure 3. For simplicity, the energy recovery system is designed with the generator operating self-cooled. The PGS-100 is attractive for its low torque compared to other manufacturers. The generator is also provisioned with keyed shaft for coupling to a prime mover and a Hall Effect sensor which can be used to measure the generator, and indirectly the turbine, speed.

Table 1: Generator Specification

Model Type Input Power Output Power Operating Speed

Heinzmann PGS100 PM Synchronous 2.0 kW 1.8 kVA 3000 RPM


Page 5 of 84

Figure 1: Heinzmann PGS100 PM Synchronous Generator

Figure 2: Heinzmann PGS100 Generator Self-Cooled Performance

0

1

2

3

4

5

6

7

0

1

2

3

4

5

0 1000 2000 3000 4000 5000 6000 7000

Torq

ue

(N

m)

Po

we

r (k

W /

kV

A)

RPM

Heinzmann PGS100 PM Generator Self Cooled

Win (kW) Wout (kVA) τ (Nm) . .


Page 6 of 84

Figure 3: Heinzmann PGS100 Generator Forced Cooling Performance

3. TURBOCHARGER REQUIREMENTS AND SELECTION

3.1. TURBOCHARGER REQUIREMENTS

The turbocharger component requirements flow down from the top level system requirements. These requirements define the mechanical coupling of the turbine shaft to the reduction gearbox, the minimum shaft power, the operating time, and the environment in which the turbine will operate. For all of the turbochargers under consideration for this application, the turbine shaft is supported by a journal bearing and this drives the need for a lubrication sub-system. In reviewing the requirements it becomes evident that selection of a turbocharger is driven primarily by the shaft power and operating time requirements. The turbochargers considered here are all produced by the same manufacturer, Honeywell Garrett, for automotive internal combustion engines, and therefore the only key difference among them is the turbomachinery itself. Functional, reliability and environmental requirements do not drive the selection of

turbocharger. The turbocharger component requirements are provided in Table 18 located in Appendix A.

3.2. TURBOCHARGER PERFORMANCE As documented in the OCAES Energy Recovery System Interim Report, the initial thermodynamic analysis of the air expansion process was performed on several turbocharger configurations, which varied in size from small to mid-sized displacement engines. The finalized operating conditions and physical constants used in the analysis are defined in Table 2:

0

2

4

6

8

10

0

1

2

3

4

5

0 1000 2000 3000 4000 5000 6000 7000

Torq

ue

(N

m)

Po

we

r (k

W /

kV

A)

RPM

Heinzmann PGS100 PM Generator Forced Cooling

Win (kW) Wout (kVA) τ (Nm) . .


Page 7 of 84

Table 2: Operating Conditions and Physical Constants

OPERATING CONDITIONS

Storage Volume, V 50.97 m3 / 1800 ft

3

Storage Pressure, P1 10 m-H2O / 202.108 kPa / 29.31 PSIA

Storage Temperature, T1 302.05 K / 28.9 °C / 84.02 °F

Pipe Length, L 500 m / 1640 ft

PHYSICAL CONSTANTS

Gas Constant 287.06 kJ/kgK

Pipe Absolute Roughness 0.002 mm

Density of Sea Water 1027.67 kg/m3

Kinematic Viscosity of Air, ν 16.12 x 106 m

2/s

From the calculated output power and rotor speed, the free power and torque curves were generated following the steps outlined in section 7.1 of the OCAES Energy Recovery System Interim Report. Torque near stall is found at 1000 RPM from:

�̇�𝑜𝑢𝑡 = 𝜏𝜔 (eq. 1) A linear equation is fitted between the torque values at stall and the torque at the running speed calculated from the defined operating conditions. The equation is extrapolated to zero rotor speed (stall) and zero torque (maximum speed). The torque equation then assumes the following form:

𝜏𝑡(𝜔) = 𝜏𝑠 − 𝜔𝜏𝑠

𝜔𝑛𝑙 (eq. 2)

Here, τs is the stall torque and ωnl is the maximum rotor speed at zero torque. The turbine power curve at a given pressure ratio and inlet temperature is then found by substituting equation (2) into the power equation:

�̇�𝑡(𝜔) = 𝜏𝜔 = − (𝜏𝑠

𝜔𝑛𝑙) 𝜔2 + 𝜏𝑠𝜔 (eq. 3)

Since power is the product of torque and rotor speed, the power is zero at the two limits of the power curve where ω = 0 (stall) and where τ = 0 (no load). The performance of each turbocharger option was compared to the power input and torque characteristics of the generator, and all the proposed turbocharger options were found to exceed the generator power and torque input requirements. It was then determined from the available turbine maps if the mass flow rates of the proposed turbochargers would meet the required run time for the energy recovery system. For all turbochargers larger than the Honeywell Garrett GT2052, the mass flow rate was found to be too large to sustain the system for the minimum required time of 10 minutes. However, the GT2052 was found to power the energy recovery system for almost 13 minutes at a pressure ratio of 2.0 increasing to almost 30 minutes if the pressure ratio is reduced to 1.25.

3.3. TURBOCHARGER SELECTION The turbocharger selected for the energy recovery system is the Honeywell Garrett GT2052 shown in Figure 4. This turbocharger has an internal wastegate which can be utilized as a backup device to limit the pressure ratio and prevent over-speed of the generator or reduction gearing. The power and torque characteristics of the GT2052 as calculated using equations (1) - (3) are presented in Figure 5 for pressure ratios of 1.25 and 1.50. It can be seen that the GT2052 exceeds the input power and torque requirements of the Heinsmann PGS100 generator at a pressure ratio of 1.25. Consequently it appears unnecessary to


Page 8 of 84

operate the GT2052 at pressure ratios higher than 1.25. In addition, the lower flow rate through the GT2052 reduces the pressure drop in the inlet piping. As a result, an inlet pipe diameter as small as 3.0 inches can feasibly be used between the storage container and the energy recovery system, saving on cost and also facilitating installation of the system within the envelope constraints. The thermodynamic performance of the GT2052 is given in Table 3 and the expected inlet pressure to the turbine for the mass flow rate achieved at a 1.25 pressure ratio is given in Table 4.

Figure 4: Honeywell Garrett GT2052

Figure 5: Power and Torque for GT2052 Turbocharger

Table 3: GT2052 Thermodynamic Analysis Results πt �̇�(√θ/δ) �̇�𝒓 (T0,2 - T0,3) �̇�𝒐𝒖𝒕 ω Run Time

ppm kg/s ppm kg/s K (°C) kW rpm min

1.25 7.19 0.05 8.78 0.07 11.19 0.61 42075 29.84

1.50 9.27 0.07 13.58 0.10 19.82 1.39 55993 19.29

0

5

10

15

20

0 10000 20000 30000 40000 50000 60000

Torq

ue

(N

m)

/ P

ow

er

(kW

)

Rotor Speed (RPM)

GT2052 Power and Torque

τ, π = 1.25

W, π = 1.25

τ, π = 1.5

W, π = 1.5

. .

.

https://turbobygarrett.com/turbobygarrett/sites/default/files/media/import/main_image/GT2052_MAIN_0.jpg


Page 9 of 84

Table 4: Inlet Air Pressure Drop (πt = 1.25, m = 0.07 kg/s)

Diameter Velocity Re ε/d f hL Static Inlet

Pressure, Pin Total Inlet

Pressure, Pt

in cm ft/s m/s

m kPa PSIG kPA PSIG

3.0 7.62 20.51 6.25 29548 1.97E-05 0.019 242.16 150.80 7.17 196.34 13.78

3.5 8.89 15.07 4.59 25326 1.69E-05 0.019 115.62 174.65 10.63 199.24 14.20

4.0 10.16 11.54 3.52 22161 1.48E-05 0.020 60.98 186.08 12.29 200.49 14.38

4.5 11.43 9.11 2.78 19698 1.31E-05 0.020 34.70 192.09 13.16 201.09 14.47

4. REDUCTION GEARING REQUIREMENTS AND SELECTION The planetary reducer was previously selected as the gearing technology as discussed in the OCAES Energy Recovery System Interim Report. The purpose of the reduction gearing is to reduce the high speed, low torque input of the turbocharger to a lower speed, high torque output for the generator. Therefore, the performance requirements driving selection of the planetary reducer are maximum input speed, gear ratio, and output torque rating. The operating environment is the same as for the generator and turbocharger. The reduction in speed is accomplished by appropriate selection of the gear ratio. The gear ratio is chosen to allow for the highest input speed from the turbocharger. Consequently, the relatively high speeds of the turbocharger necessitate a planetary reducer with a high maximum input speed. Several manufacturers of planetary reducers were considered, however nearly every company reviewed specifies maximum input speeds no greater than 8,000 RPM. Only one company, Anaheim Automation, a maker of planetary reducers for stepper, servo, and brushless DC motors, manufactures off-the-shelf planetary reducers with input speeds up to 18,000 RPM. For the Heinzmann generator, the maximum power achieved is 1.8 kVA at 3000 RPM when operating self-cooled. Although the generator can be operated at up to 6000 RPM, it does not produce additional power without forced cooling. Therefore, as the maximum working speed of the generator is limited to 3000 RPM, there is no need to drive the generator to any higher speed. The turbine shaft speed, ωin, is then found through the definition of the gear ratio:

𝐺𝑅 = 𝜔𝑖𝑛

𝜔𝑜𝑢𝑡 (eq. 4)

𝐺𝑅𝜔𝑜𝑢𝑡 = 𝜔𝑖𝑛 (eq. 5) For the selected manufacturer, Anaheim Automation, the peak input speed is 18,000 RPM. The Honeywell Garrett GT2052 turbo achieves peak power at approximately 20,000 RPM at a pressure ratio of 1.25. A gear ratio of 6 would permit the turbo to spin at the reducer maximum speed of 18,000 RPM which is close to the peak power at 20,000 RPM for a pressure ratio of 1.25. However, margin is introduced between the chosen operating speed and the maximum input speed of the reducer to reduce the possibility of over-speeding the component. A gear ratio of 5 achieves a turbine speed of 15,000 RPM for the generator speed of 3000 RPM, giving 16% margin to the maximum input speed of 18,000 RPM. The reducer must be able to transmit the required torque to the generator. Torque sizing for gearboxes begins with the design torque of the load together with a service factor, which is a rating multiplier that accounts for the duty cycle and the uniformity of the load. A service factor of 1.0 indicates that the gearbox torque may be sized to exactly match the load design torque. Service factors greater than 1.0 are multiplied by the load design torque and the resulting value becomes the torque rating requirement for the gearbox. This ensures that the selected gearbox is robust enough for the application. The expected duty is the ratio of operating time to cycle time. Operating time is defined as the sum of the acceleration, steady state, and deceleration times, depicted in Figure 6, and cycle time is sum of the


Page 10 of 84

operating time and the non-operating or pause time. Therefore the expected duty is defined as:

𝐸𝐷 =𝑡𝑜𝑝

𝑡𝑐𝑦𝑐=

𝑡𝑎𝑐𝑐+𝑡𝑠𝑠+𝑡𝑑𝑒𝑐

𝑡𝑎𝑐𝑐+𝑡𝑠𝑠+𝑡𝑑𝑒𝑐+𝑡𝑝 (eq. 6)

Figure 6: Generalized Operating Time for Planetary Reducer

For the recovery system with the turbocharger operating at a pressure ratio of 1.25, the times are expected to be as shown in Table 5 and Figure 7 when operating at a turbine pressure ratio of 1.25 maximum:

Table 5: Energy Recovery System Cycle Time

Step Time

Cycle, tcyc 62 min

Acceleration, tacc 1 min

Steady State, tss 30 min

Deceleration, tdec 1 min

Pause, tp 30 min

Figure 7: Cycle Time of OCAES Energy Recovery System

0

1

0 1

ω/ω

ss

t/tcyc

Cycle Time Definition

tacc tp tss tdec

0

1000

2000

3000

0 10 20 30 40 50 60

Ge

ne

rato

r Sp

ee

d

Cycle Time

Energy Recovery System Cyce Time


Page 11 of 84

Substituting times from Table 5 into equation (6) gives an expected duty of 51%. Expected duties of less than 60% and operating times greater than 20 minutes can be considered continuous operation. Load classification describes the shock severity of the load on the reducer. High cyclic utilization (many stop/start cycles) and reciprocating engines are generally classified as moderate to severe shock. Continuously operating machines (defined from the expected duty), centrifugal turbomachinery and electric generators are generally classified as uniform. For this application, the expected duty can be considered continuous and the load is an electric generator, therefore the load classification is uniform and a service factor of 1.0 can be applied to the torque rating. Based on the generator torque requirements specified in Figure 2 and the turbocharger speeds, the selected gearbox is specified in Table 6. Lubrication for this reducer is self-contained and requires no servicing.

Table 6: Anaheim Automation Planetary Reducer Specification

Model Gear Ratio Generator Torque Rated Torque Max Input Speed

GBPN-0401-005 5 3 – 7 Nm 14 Nm 18,000 RPM

Figure 8: Anaheim Automation GPBN-0401 Planetary Reducer

5. SUBSYSTEM DESIGN

5.1. MECHANICAL COUPLING Mating the turbine output shaft to the planetary gear reducer is accomplished by a coupling adapter. The concept for the coupling adapter is a simple rod which is internally threaded on one end for installation onto the turbine shaft. The other end is inserted into the bushing of the planetary reducer, which acts as a frictionally engaged coupling. The bushing engages the rod by tightening the clambing screw on the reducer. Wrenching flats are machined into the rod at the internally threaded end to facilitate holding the rod with tooling. A conceptual design of the coupling adapter is shown in Figure 9 and a 2-D draft with nominal dimensions is shown in Appendix B. A detailed design used to fabricate a part would require additional stress analysis to ensure the part has the required strength and dimensional tolerancing.


Page 12 of 84

Figure 9: Adapter Coupling Concept

Both the planetary reducer and the generator employ keyed shafts and therefore require an additional coupling to link the two shafts and transmit torque. There are many types of mechanical couplings available; a hub-and-spider configuration is selected for this application because of its low inertia, high torque transmission and shock absorption. Sizing of the spider follows a procedure similar to the planetary reducer were the nominal and maximum torques of the load are multiplied by a service factor which accounts for environment, shock, and starting frequency. An aluminum size 19 spider coupling manufactured by KTR is selected for this system as specified in Table 7 and shown in Figure 10.

Table 7: KTR Spider Coupling Specification

Size Hub Material Spider Hardness

Hub 1 (Reducer)

Hub 2 (Generator)

Rated Torque Max Torque

19 Aluminum 98 Sh-A Type 1.0, 10 mm Bore

Type 1.0, 19 mm Bore

17 Nm 34 Nm

Figure 10: Spider Coupling

Aluminum Hub (Reducer Side)

Aluminum Hub (Generator Side)Polyurethane Spider


Page 13 of 84

5.2. TURBOCHARGER MODIFICATION Since the turbine shaft of the turbocharger will be used to drive the planetary reducer, modifications to the compressor side of the turbocharger are required to connect the shaft to the reducer. The modifications are straightforward and are illustrated in Figure 11. First, the compressor volute is removed. The compressor backplate is retained since it provides axial support and oil sealing of the shaft. The impeller is removed next by removing the locknut and sliding the impeller off the shaft. The coupling adapter rod is then threaded onto the turbine shaft. It should be noted that the impeller locknut is self-locking, so that it does not lose torque and loosen during operation. The same retention can be achieved with the coupling adapter either by coating the turbine shaft threads with a thread locking compound prior to installing the adapter coupling rod, or by employing a self-locking threaded insert in the unthreaded bore of the coupling rod as opposed to tapping the rod with internal threads. With the latter alternative, the diameter of the turbine end of the coupling rod may need to increase to accommodate a threaded insert. The general consensus is that the impeller locknut is torqued to 18-20 in-lb, therefore the coupling rod should be torqued to within the same range in lieu of a torque requirement provided by the turbocharger manufacturer, Honeywell Garrett.

Figure 11: Turbocharger Modification

Compressor volute removed.

Compressor impeller removed.

Adapter coupling installed.Planetary reducer

connected.

Assembled turbocharger


Page 14 of 84

5.3. TURBOCHARGER LUBRICATION

5.3.1. LUBRICATION SYSTEM REQUIREMENTS Lubrication for the turbocharger journal bearing is provided by a dedicated, separate oil system. Requirements for the oil system are that it must provide oil to the turbocharger at the needed flow rate and pressure. It must also store the oil, prevent contamination, and maintain the oil temperature at an acceptable level. The oil system requirements are defined in Table 19 in Appendix A. The system includes a storage tank, feed pump, filter and cooler. There is no active scavenging of the return oil, therefore the return line to the tank must always route to a lower elevation than the turbocharger. A pressure and temperature gauge are also included to monitor oil flow into the turbo. The oil system schematic is shown below in Figure 12. It is seen that the smaller supply line to the turbocharger is tapped off of a main recirculation flow which runs through the oil cooler.

Figure 12: Turbocharger Lubrication System

Rotary Gear Pump

Finned TubeHeat Exchanger

Pressure Gauge

10 Micron Filter

Temperature Sensor

Baffled Tank

Dessicant Breather

Turbocharger Center Bearing Housing

Drain

Oil Feed

Surplus Recirculation

Oil R

eturn


Page 15 of 84

5.3.2. LUBRICATION SYSTEM COMPONENT SELECTION Investigation of turbocharged internal combustion engines finds that typical oil flow rates and pressures for journal bearing turbos are 0.5 - 0.8 gpm at 40 – 60 psig as stated by various turbocharger manufacturers. Rotary gear pumps are typically used for oil feed pumps. The principle challenge for the feed pump in this system is the power source to drive the pump. Automotive pumps are typically belt driven, however a belt drive is considered too cumbersome to implement given the installation envelop and added complexity to the design. An electric powered pump is chosen for the comparative ease of installation and operation. An example gear pump is the Oberdorfer S4000L, shown in Figure 13. The performance curve for this gear pump is shown in Appendix C. As specified in Table 8, the pump pressure rise is 40 – 50 psig at a flow rate of 1.75 – 2 gpm, drawing just over .25 hp (186 W) at that operating condition.

Figure 13: Oberdorfer S4000L Gear Pump

Table 8: Oberdorfer Gear Pump Specification

Model Number Flow Rate Pressure Rise Power Draw

S4000L 1.75 – 2 gpm 40 – 50 psig .25 hp (186 W)

An additional design challenge is maintaining the oil temperature at an acceptable level. Although there is no specific data available for oil temperature as a function of time or rotation speed for the GT2052 turbocharger, Reference [5] documents oil temperatures on a turbocharged diesel engine operating at the following speeds:

Engine Speed Oil Temperature 1000 55 °C 3000 115 °C

This investigation, however, considered exhaust gas temperatures of 550 K and rotor speeds of over 100,000 RPM. The energy recovery system will not subject the turbocharger to conditions anywhere near as severe; however the data from reference [5] is used to estimate what the upper temperatures might conceivably reach with a turbocharger in normal use. An oil cooler is included in the lubrication system to ensure the oil is held to within acceptable limits. It is expected forced air will be required in order to achieve adequate cooling, and so an electric fan is also included in the system. Selecting the oil cooler requires at a minimum knowledge of the oil flow rate, air velocity through the cooler and the desired temperature drop. In turn, the specific heat and density of the lubricating oil are also needed to complete the design. For several oil weights, specific heat and density were found to be as follows:


Page 16 of 84

Table 9: Properties of Automotive Engine Lubricating Oils

Lubricating Oil Specific Heat, Cp (kJ/kg) Density, ρ (kg/m3)

SAE 10 1.90 875

SAE 30 1.90 875

SAE 10W30 2.34 824

For the initial design of this system, the temperature drop is related to the heat removed from the oil by:

�̇� = �̇�𝐶𝑝∆𝑇 (eq. 8)

The specific heat and density were averaged for the three oil weights to obtain a baseline result for the heat removal. The flow rate is chosen as 2 gpm in order to make use of the proposed manufacturer’s data sheets, however actual flow rate through the turbocharger bearing will be between 0.5 – 0.8 gpm and so this analysis is conservative. Parameterizing the temperature drop ΔT, the required heat removal is:

Table 10: Lubricating Oil Heat Removal

Temperature Drop, ΔT (°C) Volumetric Flow Rate, �̇� (gpm) Heat Removed, �̇� (kW)

5 2 1.1

10 2 2.2

15 2 3.3

20 2 4.5

The fan is 10 inches in diameter and is specified to move 775 CFM of air. At the specified diameter and volumetric flow rate, the velocity is found by solving:

�̇� = 𝐴𝑣 (eq. 9) The velocity is calculated to be 23 m/s. The performance data from the manufacturer, Earl’s Performance, indicates approximately 10 BTU/min (175 W) per tube in the proposed oil cooler. Coolers with tubes ranging from 7 to 60 are available. A 25 tube cooler very nearly achieves the 20 °C temperature drop at 4.4 kW while the 19 tube cooler exceeds the 15 °C drop at 3.34 kW. With the lower flow rate expected in actual operation, and to save on cost, the 19 tube cooler is chosen.

Table 11: Earl's Performance Oil Cooler Specification

Model Number Number of Tubes Flow Rate Heat Removed

41900 19 2 gpm 3.3 kW


Page 17 of 84

5.3.3. LUBRICATION SYSTEM ELECTRICAL POWER

Electrical power to the pump motor is to be provided by a 12 V battery. A battery is chosen as the primary power supply for the gear pump because the turbocharger bearing requires oil pressure immediately at startup, and the generated power during the transient acceleration period may be unstable or inadequate for the gear pump motor. Furthermore, in the event the generated power cannot be used, a battery otherwise permits continued operation of the system. To size the battery, we first estimate the electrical load from the gear pump motor. At the expected operating point of 1.75 gpm, 50 psig, and .25 hp, the current draw is found by solving: 𝑃 = 𝐼𝑉 (eq. 7) Assuming a motor efficiency of 75%, the expected current draw is 20.67 A at 12 VDC. This agrees with published full load current draws of 21 A for commercially available ¼ hp 12 VDC motors. In addition, the fan draws 5A of current at 12 V and so the total current draw on the battery is 25.67 A. Therefore a 12 V battery with a capacity of 50 Ah minimum would provide sufficient power to operate the system for the design goal of 1 hour per day. A capacity of at least twice the expected load optimizes battery life by ensuring the battery is not depleted past 50% during normal use. It is desired to utilize part of the generated electrical power to recharge the battery while the energy recovery system is in steady state operation. This will mitigate servicing of the battery and extends the operating time of the energy recovery system. As the system will generate up to 1.8 kVA at 100 VAC, charging the battery using the system power requires rectifying the 3 phase AC to DC and stepping the generator voltage down to approximately 14V. In addition, a charge controller is needed to manage the charge current to the battery. The three generator phases are wired to a rectifier which converts the 3 phase AC to DC. The DC output from the rectifier then passes through the step-down transformer. The transformer is a buck DC converter type sized for 400W at 110 VDC, accommodating the power draw of the gear pump motor. Voltage is stepped down from 110 to 14 VDC. A regulator maintains the transformed voltage at the required magnitude. The 14 VDC rectified power is wired to the charge controller input and from the charger controller to the battery. A basic electrical schematic for the lubrication system is shown in Figure 14.

Figure 14: Lubrication System Electrical Schematic

DC-DC Converter110 / 14 V

12 V

Ch

arge

C

on

tro

ller

Vo

ltag

e R

egu

lato

r

To Electrical Loads

RectifierPM Syncrhonous

Generator


Page 18 of 84

Table 12: Electrical System Component Specification

Component Model Voltage Rating (v) Current Rating (A) Comments

Rectifier Gigu G-R-100 1600 100

DC-DC Converter Vicor V72A15E400 110 / 15 26.7 Built-in regulator

Charge Controller Flexcharge NC25A-12 12 / 24 / 36 25 A

Battery BattaMax BAT-ML12-080 12 80 Ah Lead-acid AGM

Figure 15: 3 Phase Rectifier and DC-DC Converter

Figure 16: Charge Controller and Battery


Page 19 of 84

6. INSTRUMENTATION AND CONTROL The recovery system is instrumented to monitor performance parameters. This will allow the system’s actual performance to be compared to the theoretical performance as designed. The following parameters are instrumented:

Inlet air mass flow rate

Inlet air pressure (total and static)

Inlet air temperature

Outlet air temperature

Generator speed

Generator voltage

Generator current

Generator Frequency Requirements for instrumentation include accuracy, range, resolution and the operating environment, the fidelity of which depends on the demands of the measurement. Accuracy is the principle performance requirement and is always specified as a lower limit of performance; instrumentation of higher accuracy is always acceptable whereas lower accuracy must be ascertained for suitability to the measurement. Table 13 defines the range, accuracy and resolution requirements for required instrumentation. The instrumentation must also meet environmental requirements specified for the system.

Table 13: Instrumentation Requirements

Parameter Range Accuracy Resolution

Pressure 0 – 50 psia 1% Full Scale or better 0.01 psia

Temperature 32 – 122 °F / 0 – 50 °C 1% Full Scale or better 0.1 °F / °C

Flow Rate 0 – 500 ACFM 1% Full Scale or better 0.01

Rotational Speed 0 – 50,000 RPM 0.1% Full Scale or better 1 RPM

Voltage 0 – 200 V 1% Full Scale or better 0.01 V

Current 0 – 100 A 3% Full Scale or better 0.1 A

Frequency 0 – 500 Hz 1% Full Scale or better 0.1 Hz

Inlet air mass flow rate and pressure will provide data to determine the turbocharger’s pressure ratio and flow rate, which can be compared to the turbine map provided by the manufacturer. The pressure ratio, combined with the inlet and outlet air temperatures, allow for the calculation of the specific work. Since it is the total pressure which defines the turbine pressure ratio, ideally, this parameter would be measured directly with a pitot probe. However, outside the laboratory setting a pitot probe may not be feasible within the installation constraints, as flow straighteners, straight lengths of duct of 8D – 10D, and a minimum pipe diameter of at least 30D are recommend for accurate pitot probes measurements. Alternatively, static pressure can be simply measured with a gauge and used as a reference parameter in controlling turbine speed with the generator speed indication providing the primary means of control as described below. Nevertheless, options for both a pitot probe and pressure gauge are presented in Figure 17 and Appendix D.


Page 20 of 84

Figure 17: System Instrumentation Control of the energy recovery system is manual with automatic limiters preventing over-speed. The principle parameters used to control the system are inlet pressure and generator speed. The turbine speed is controlled to the design value by manually regulating the pressure ratio across the turbine rotor and monitoring the generator speed. The pressure of the inlet airflow is set with a pressure regulator. A gauge (or pitot probe) downstream of the pressure regulator valve indicates the inlet pressure to the turbine. When it is observed that the generator is operating at the intended speed of 3000 RPM, it is then known that the turbocharger is spinning at the design speed of 15,000 RPM from the planetary reducer gear ratio. The inlet pressure and temperature at this condition establishes the operating pressure and temperature ratios across the turbine. In addition to the pressure regulator, there are two other devices for safety limiting and shut down of the system. The first is a shutoff control valve installed just upstream of the pressure regulator. This valve is intended to be operated in only two discrete positions, full open and full closed. When open, air pressure is provided to the regulator energizing the system. When closed, the valve shuts off the inlet air flow and de-energizes the system, effectively commanding the system off. The second device is the internal wastegate on the GT2052 turbocharger. The wastegate is a valve integral to the turbine volute which is operated automatically by a pneumatic actuator. A small line downstream of the pressure regulator is plumbed from the turbine inlet duct to the wastegate actuator for sensing inlet air pressure. During operation, if the inlet pressure exceeds an established set point, the actuator drives the wastegate valve open allowing air to bypass around the turbine thereby limiting turbine speed. The actuator pressure set point is adjustable to accommodate any changes in the system that would require a higher or lower turbine speed.

Temperature Sensor

Air Flow Meter

Pressure Regulator

Shutoff Valve

Turbocharger

Temperature Sensor

Hall Sensor(Generator Speed)

Voltmeter

G

PM Synch GeneratorAmmeter

Min length 10D Min length 5D

Exhaust

Inlet

Pressure Gauge

Measuring Static Inlet Pressure with Gauge

Pitot Probe

Temperature Sensor

Pressure Regulator

Shutoff Valve

Turbocharger

Temperature Sensor

Hall Sensor(Generator Speed)

Voltmeter

G

PM Synch GeneratorAmmeter

Min length 8.5D Min length 10D

Exhaust

Inlet

Min length 5D

Measuring Total Inlet Pressure with Pitot-Static Probe

Air Flow Meter


Page 21 of 84

7. FINAL SPECIFICATION AND OPERATING PARAMETERS

7.1. OCAES ENERGY RECOVERY SYSTEM BILL OF MATERIALS The energy recovery system is specified as follows in Table 14 and is illustrated in Figure 18. The data sheets for all components used on the system are provided in Appendices B through D.

Table 14: OCAES Energy Recovery System Bill of Material

Component Manufacturer Model Quantity

Recovery System

Turbocharger Honeywell Garrett GT2052 1

Planetary Reducer Gearbox Anaheim Automation GPBN-040 1

PM Synchronous Generator Heinzmann PGS100 1

Coupling Adapter Rod Custom N/A 1

Spider Coupling KTR Rotex Al No. 001 1

Turbocharger Lubrication System

Gear Pump Oberdorfer S4000L 1

Oil Filter Various 10 Micron Spin On 1

Oil Cooler Earl’s Performance 42900 1

Tank Various 2 Gallon 1

Tank Breather Element McMaster-Carr 9833K22 1

Fan AllStar Performance ALL30070 1

Battery WindyNation BattaMax BAT-ML12-080 1

Rectifier Gigu G-R-100 1

Transformer Vicor V72A15E400 1

Charge Controller Flexcharge USA NC25A-12 1

Instrumentation

Air Flow Meter Flow Technology FT-48 1

Pressure Gauge Dwyer DPGA-07 41

Pitot Probe (Optional) Dwyer 167-6 1

Digital Temperature Sensor Dwyer DBTA3252 32

Volt Meter Fluke 381 1

Ammeter Fluke 381 1

Frequency Sensor Fluke 381 1

NOTE 1: Includes quantities for system pressure, oil pressure, and system with pitot probe option. Use of pitot

probe requires 2 gauges and/or transducers to indicate sensed pressures. NOTE 2: Includes quantities for working fluid temperature of energy recovery system and oil temperature.


Page 22 of 84

Figure 18: OCAES Energy Recovery System

7.2. OCAES ENERGY RECOVERY SYSTEM OPERATING PARAMETERS The expected nominal operating point of the system is defined in Table 15:

Table 15: OCAES Energy Recovery System Operational Parameters

Parameter Value

Inlet Pressure / Pressure Ratio 18.4 PSIA max / 1.25 max

Inlet Temperature 28.9 °C

Turbine Shaft Power 2 kW

Turbine Speed 15,000 RPM Max

Generator Speed 3000 RPM Max

Generated Electrical Power 1.8 kVA Max

8. COMMENTS The end-system defined by this design should be considered a first iteration pass in the systems engineering process. The solution that is presented herein shows how the end-system desired by the stakeholder is decomposed into functional and performance requirements and then given definition by the specification of various design solutions. Within the resources available to complete this design, many assumptions were made and other design aspects were intentionally omitted because either the necessary information was unavailable, or those aspects of the design were not seen as critical to illustrate the overall concept of the system solution. For example, the dynamics of the various rotating components were not given rigorous consideration here, nor were the axial and radial bearing loads on the equipment, nor the installation and routing of fluid lines and ducting. Only the conversion of energy as it is transferred from the turbocharger to the generator was the primary engineering concern. However, in this or any such system each of these issues must be thoroughly considered in the final design to ensure the system will meet performance targets and not fail prematurely. It is hoped that this work will provide an adequate baseline from which a functionally viable, cost effective energy recovery system can be developed, constructed and deployed to real-world benefit.

GT2052 Turbocharger

Air Inlet

Air Exhaust

PGS100 Generator

Reducer-Generator Coupling

Turbine Shaft-Reducer Coupling

Wastegate Actuator

Oil Discharge

Planetary Reducer Gearbox

Oil Inlet


Page 23 of 84

9. REFERENCES

1. Cohen, H., Rogers, G., Saravanamutto, H. Gas Turbine Theory. 3rd

Ed. New York: John Wiley & Sons, 1987. Print.

2. Darvell, B. W., and Dyson, J. E. “Torque power and efficiency characterization of dental air turbine handpieces.” Journal of Dentistry. Vol. 27, 1999, pp. 573 – 586.

3. Finch, Kemit. “Design of an Energy Recovery System for an Ocean Compressed Air Energy Storage Technology Demonstrator – Interim Report.” NC State University Dept. of Mechanical and Aerospace Engineering. (Master’s Project) 2016.

4. Korakianitis, Theodosios, Wilson, David Gordon. The Design of High-Efficiency Turbomachinery and Gas Turbines. 2

nd Ed. Upper Saddle River: Prentice Hall, 1998. Print.

5. Martinez-Botas, Ricardo, and Romagnoli, Alessandro. “Heat Transfer Analysis in a Turbocharger Turbine: An Experimental and Computational Evaluation.” Applied Thermal Engineering. Vol. 38, 2012, pp 58 – 77.

6. Noor, A. B. Mohd and Whitfield, A. “Design and performance of vaneless volutes for radial inflow

turbines. Part 1: non-dimensional conceptual design considerations.” Journal of Power and Energy. Vol. 208, 1994, pp. 199-211.


Page 24 of 84

APPENDIX A REQUIREMENTS AND COMPLIANCE MATRICES


Page 25 of 84

Table 16: Generator Requirements and Compliance Matrix

ID NAME TYPE REQUIREMENT STATEMENT SPECIFICATION COMPLIANCE

FUNCTION

Gen.F1 Generator Type Function

The generator shall be permanent magnet synchronous type PM Synchronous

Complies

Gen.F2 Mechanical Interface Function

The generator shall be provisioned with a keyed shaft for mechanical coupling. Keyed Shaft

Complies

Gen.F3 Speed Function Generator shall be provisioned for speed measurement Integrated Hall Sensor

Complies

PERFORMANCE

Gen.P1 Generated Power Performance

Generator shall produce a minimum of 1.5 kW electric power. 1.8 kW at 3000 RPM

Complies

Gen.P2 Generated Voltage Performance

Voltage at generator terminals shall be 100 VAC minimum. 110 VAC 3 Phase

Complies

Gen.P3 Maximum Torque

Performance Interface

The required input torque to the generator shall not exceed 14 N-m maximum.

6.66 Nm max with self-cooling, 8.34 Nm max with forced cooling

Complies

RELIABILITY

Gen.R1 Duty Cycle Reliability Generator shall be capable of continuous duty. Continuous Duty Rating

Complies

Gen.R2 Operational Life Reliability

Generator shall have an operational life of at least 20,000 hours. 20,000 hrs

Complies

ENVIRONMENT

Gen.E1 Ambient Temperature Environmental

Shall operate in ambient temparture ranging from -10 °C to 40 °C. Rated -25 °C to 40 °C.

Complies

Gen.E2 Humidity Environmental

Enclsosure shall protect equipment from ingress of moist air.

IP54 Enclosure or better. Complies

Gen.E3 Water-proofness Environmental

Enclosure shall protect equipment from splashing water.


Gen.E4 Fluid Compatibility Environmental

Enclsoure shall be compatible with lubricating motor oil at 100 °C.

Enclosure constructed from aluminum. Complies

Gen.E5 Sand and Dust Environmental

Enclsosure shall protect equipment from ingress of dust.


Gen.E6 Fungal Growth Environmental

Enclsoure shall not promote growth of fungus


Gen.E7 Salt Corrosion Environmental

Enclosure shall protect equipment from salt water spray.

IP54 Enclosure or better. Enclosure constructed from aluminum.

Complies


Page 26 of 84

Table 17: Planetary Gear Reducer Requirements and Compliance Matrix


FUNCTION

Gear.F1 Gearbox Type Function The gearbox shall be a planetary reducer type.

Planetary Reducer Gear Train Complies

Gear.F3 Gear Ratio Function The gearbox shall have a gear ratio of 5 5 Complies

PERFORMANCE

Gear.P1 Max Input

Speed Performance

The gearbox shall have a maximum input speed of 18,000 RPM minimum. 18,000 RPM Complies

Gear.P2 Torque Rating Performance

The gearbox shall have a torque rating of at least 8.5 Nm minimum. 14 Nm Complies

RELIABILITY

Gear.R1 Duty Cycle Reliability Gearbox shall be capable of continuous duty. Continuous Duty Rating Complies

Gear.R2 Operational

Life Reliability

Generator shall have an operational life of at least 20,000 hours. 30,000 hours Complies

ENVIRONMENT

Gear.E1 Ambient

Temperature Environment

Shall operate in ambient temparture ranging from -10 °C to 40 °C. -20 °C to 90 °C. Complies

Gear.E2 Humidity Environment

Enclsosure shall protect equipment from ingress of moist air. IP54 Enclosure or better. Complies

Gear.E3 Water-

proofness Environment Enclosure shall protect equipment from splashing water. IP54 Enclosure or better. Complies

Gear.E4 Fluid

Compatibility Environment Enclsoure shall be compatible with lubricating motor oil at 100 °C. IP54 Enclosure or better. Complies

Gear.E5 Sand and

Dust Environment Enclsosure shall protect equipment from ingress of dust. IP54 Enclosure or better. Complies

Gear.E6 Fungal Growth Environment

Enclsoure shall not promote growth of fungus IP54 Enclosure or better. Complies

Gear.E7 Salt

Corrosion Environment Enclosure shall protect equipment from salt water spray. IP54 Enclosure or better. Complies


Page 27 of 84

Table 18: Turbocharger Requirements and Compliance Matrix


INTERFACE AND INSTALLATION

Turb.I1.1 Mechanical

Interface Interface

The turbine shall be provisioned with an adapter coupling to mate the turbine shaft to a gear reducer.

Custom coupling adapter Complies

FUNCTION

Turb.F1.1 Turbine

Configuration Function

The turbine shall provide shaft power to drive an electrical generator.

Honeywell Garrett GT2052: 6.56 kW at πt = 1.25 and 15,000 RPM Complies

Turb.F1.2 Overspeed / Rotor Burst Function

Turbine speed shall be limited to 15000 RPM maximum under load.

Honeywell Garrett GT2052: internal wastegate Complies

PERFORMANCE

Turb.P1.1 Generated

Power Performance

The turbine shall be capable of producing sufficient shaft power to drive a 1.8 kVA. PM synchronous generator at 3000 RPM operating at 90% efficiency.

Honeywell Garrett GT2052: 6.56 kW at πt = 1.25 and 15,000 RPM Complies

Turb.P1.2 Operating

Time Performance

The turbine shall provide the required shaft power for a minimum of 10 minutes in steady state operation.

Honeywell Garrett GT2052: 30 minutes of operation at πt = 1.25 Complies

Turb.P1.3 Working Fluid Performance

Constraint

The turbine shall provide the required shaft power when operating with unconditioned atmospheric air as the working fluid.

Honeywell Garrett GT2052 configuration Complies

Turb.P1.4 Air Volume Performance

Constraint

The turbine shall meet the operating time requirement when provided with a total air volume of 50 m

3.


Turb.P1.5 Operating Pressure

Performance Constraint

The turbine shall provide the required shaft power when operated with air compressed under a 10 m column of sea water and conveyed through 500 m of inlet piping.


Turb.P1.6 Operating

Temperature Performance

Constraint

The turbine shall provide the required shaft power when operating with air at a temperature of 43 °F – 81 °F (6°C – 27 °C)


ENVIRONMENT

Turb.E1.1 Ambient


The turbine shall operate in ambient temparture ranging from -10 °C to 40 °C.


Turb.E1.2 Humidity Environment

The turbine performance shall be unaffected when operating with or by the exposure to moist air.



Page 28 of 84


Turb.E1.3 Water-proofn

ess Environment

Turbine performance shall be unaffected when operating with or by the exposure to splashing water.

Honeywell Garrett GT2052 configuration

Complies

Turb.E1.4 Sand and

Dust Environment

Enclsosure shall protect equipment from ingress of dust.

Honeywell Garrett GT2052 configuration

Complies

Turb.E1.5 Fungal Growth Environment

Turbine materials shall not promote the growth of fungus.


Turb.E1.6 Salt

Corrosion Environment Turbine shall be protected from exposure to salt water spray.


Table 19: Lubrication System Requirements and Compliance Matrix

ID Name Type Statement Specification Compliance

INTERFACE AND INSTALLATION

Lube.I1.1 Drain Line

Routing Installation

Oil drain line shall plumb to tank return port at lower elevation than turbocharger oil outlet port at all locations.

Routed lower than turbo oil outlet Complies

FUNCTION

Lube.F1.1 Power Source Function

Shall operate on 12 VDC electrical power up to 400 W maximum.

12 V Battery charged by the energy recovery system Complies

Lube.F1.2 Oil Feed Function Shall prevent entrainment of air into tank outlet port.

Baffled Tank separates feed and return lines. Complies

PERFORMANCE

Lube.P1.1 Generated

Power Performance

Shall provide oil to the turbocharger bearing at a flow rate of 0.5 – 0.8 gpm at 40 – 60 psig. S4000L Gear Pump Complies

Lube.P1.2 Operating Time Performance Shall maintain oil inlet temperature to less than 100 °C

41900 Oil Cooler and Fan Complies

ENVIRONMENT

Lube.E1.1 Ambient


The system shall operate in ambient temparture ranging from -10 °C to 40 °C. S4000 L Gear Pump Complies

Lube.E2.1 Humidity Environment Shall minimize exposure of oil to humid air.

Sealed system. Tank has breather to relieve pressure differentials. Complies

Lube.E2.2 Humidity Environment

System components shall be unaffected by exposure to humid air.

Enclosures rated to IP54 or better. Complies

Lube.E3.1 Waterproofness Environment Shall protect oil from water contamination.


Lube.E3.2 Waterproofness Environment System components shall be protected from splashing water.



Page 29 of 84

ID Name Type Statement Specification Compliance

Lube.E4.1 Sand and Dust Environment Shall protect oil from sand and dust contamination.


Lube.E4.2 Sand and Dust Environment

System components shall be protected from sand and dust contamination


Lube.E5.1 Fungal Growth Environment System shall not promote fungal growth.

Sealed system. Constructed from non-fungus nutrient materieals. Complies

Lube.E5.1 Salt Corrosion Environment Shall protect oil from exposure to salt water sparay.


Lube.E5.2 Salt Corrosion Environment

System components shall be protected from exposure to salt water spray.



Page 30 of 84

APPENDIX B ENERGY RECOVERY SYSTEM COMPONENT DATA SHEETS


Page 31 of 84


Page 32 of 84


Page 33 of 84


Page 34 of 84


Page 35 of 84


Page 36 of 84


Page 37 of 84


Page 38 of 84

6.0 mm

3.6 mm50 mm

25 mm 7.9 mm

15 mm

3.6 mm


Page 39 of 84


Page 40 of 84


Page 41 of 84

APPENDIX C TURBOCHARGER OIL SYSTEM COMPONENT DATA SHEETS


Page 42 of 84


Page 43 of 84


Page 44 of 84


Page 45 of 84


Page 46 of 84


Page 47 of 84


Page 48 of 84


Page 49 of 84


Page 50 of 84


Page 51 of 84

APPENDIX D INSTRUMENTATION DATA SHEETS


Page 52 of 84


Page 53 of 84


Page 54 of 84


Page 55 of 84


Page 56 of 84


Page 57 of 84


Page 58 of 84


Page 59 of 84

APPENDIX E OCAES Energy Recovery System Interim Report


Page 60 of 84


Page 61 of 84


Page 62 of 84


Page 63 of 84


Page 64 of 84


Page 65 of 84


Page 66 of 84


Page 67 of 84


Page 68 of 84


Page 69 of 84


Page 70 of 84


Page 71 of 84


Page 72 of 84


Page 73 of 84


Page 74 of 84


Page 75 of 84


Page 76 of 84


Page 77 of 84


Page 78 of 84


Page 79 of 84


Page 80 of 84


Page 81 of 84


Page 82 of 84


Page 83 of 84


Page 84 of 84

ocaes energy recover system final report_12-05-2016

Documents