Four Points Engineering and Design

Project 99.04: Heat Pump Design for Whalen Co.

FPED Team Members:

Ricardo Blackett, Andy Parke, Scott Quirico, Brian Zigmond

Heat Pump Design

• Team 4

– Ricardo Blackett : blackett@udel.edu

– Andrew Parke : aparke@udel.edu

– Scott Quirico : scottq@udel.edu

– Brian Zigmond : bzigmond@udel.edu

Customer: Whalen Co.Advisor: Dr. Keefe

Presentation Agenda

1. Introduction and background revisited.2. Method a. Metrics b. Benchmarks c. Concepts3. Schedule

Project Background

• By 2000, ARI will require that no standing water be allowed in HVAC systems.

• This prompts Whalen Co., manufacturer of HVAC equipment specifically for high-rise buildings, to redesign the current condensate drip pan in their vertical water source heat pump.

• In the redesign, other improvements were suggested...

Thus, the problem as presented to FPED has 3 components:

• Eliminate the standing water in the condensate drain pan of the unit.

• Improve the circulation in the “two room” units.

• Lower the operating noise level.

Mission

• In the allotted time and as economically as possible FPED will:

1. Eliminate standing water in Whalen’s vertical heat pump

2. Decrease unit’s noise level

3. Improve circulation in the two-room units

Our Approach

ProjectRequirements

Whalen’s problem

CompetitiveBenchmarking

PresentFPED’s Solution

to Whalen Co.

DevelopConcept

Produce a unit that:• eliminates standing water• is quieter• has improved room circulation

We Are Here

Constraints

Size and geometry of unit and enclosure.Regulatory commission specifications. (ARI, UL)

Customers and Wants

• Internal to Whalen• Executive

• Production

• Sales

• Engineering• External • Consumer• NCDA

• Affordability, improved circulation.

• Ease of fabrication / installation.

• Affordability, improved circulation.

• Improved circulation, ease of fabrication.

• Affordability, quiet

• Design process

Metrics and Target Values• Cost of Materials

• Cost of Manufacturing

• Air Changes per Hour in Adjacent Room

• Number of Parts

• Assembly Line Costs

• Fabrication Time

• Installation Time

• Down Time

• Repair Time

• Decibel Level

• Grade

• About $15 per pan

• About $52 per pan

• > 0

• About 12

• Minimum

• 1/2 hour/pan

• 1/2 hour/pan

• Minimum

• 4 Hours

• Less than Current Value

• A

System Benchmarking: Competitors and Best Practices...

• Trane: Well insulated unit gives quiet performance, removable drain pan for easy maintenance.

• ClimateMaster: Removable chassis for easy maintenance, sound-suppressing baffles on intakes.

Drain Pan Insert

Materials selection is in progress. Ease of manufacturing and cost of materials is being considered.

Actual geometry of insert to be determined upon physical inspection of unit.

Two Room Air Draw

Two Room Air Draw continued…

• Extend the width of the enclosure slightly to allow ducting of air flow from both rooms.

• Relocation of existing cooling coil within heat pump to accommodate return in rear of unit.

Sound Suppression Benchmarking

• Elastomer Isolators– Use natural rubber to

absorb vibration and shock to reduce noise

– Directly incorporated into the structural components of unit

– Installed in series or parallel for greater load capacity

• External Sound Attenuator– Combination of

baffles and insulation that attaches to ductwork

– Mainly used in industrial applications

Sound Suppression Concepts

• Insert neoprene or rubber insulating mat between unit and floor to eliminate noise from vibrations.

• Isolate fan and compressor motor from chassis through grommets and mountings.

• Improve or add insulation to unit.

• Attach external sound attenuator.

Sound Suppression Evaluation

Budgeting

• The established budget from Mr. Whalen is to “provide a unit and any and all materials needed within reason.”

• Through FPED’s efforts to minimize all costs, and NCDA’s experience, past agreements similar to this method have been successful.

ACTUALLY Since Last Time...

…And Until the Next Time

The Big Picture

Who Done It……..

• Ric- keep minutes of meetings, scheduler, SSD

• Zig- HVAC, competitor tracking, spokesman

• Scott-Mediator, functional benchmarking

• Andy-machine shop, materials, target values for metrics