ml pcw presentation
TRANSCRIPT
Microelectronics Lab
Process Cooling WaterGroup: Facilities Services DepartmentTeam Members: Michael Postler and Craig GuenetteStart Date: September 08, 2009
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Table of Contents The System
Commencement
As-Built Updates LPL
As-Built Updates FAB
Setup for Calculations
Existing Calculations
Existing Suggestions
Problems to be Solved
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Solutions
New Design
New Pipe Routes
Proposals
Proposals (continued)
New Calculations
Selection
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The System What is Process Cooling Water?
What is this system used for?
How does it differ from Chilled Water?
Why is it advantageous?
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Commencement Initial assignment
Update As-Built drawings
Calculate existing head loss
Make design suggestions
New condition 250 GPM 330 GPM
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As-Built Updates LPL Briefed on the “potential” hazards in ML
Field surveyed in Lower Process Level
Updated As-Built drawings
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As-Built Updates FAB Coordinated a visit to the clean room
Field surveyed in upper process level
Updated As-Built drawings
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Setup for Calculations Assigned numerical values for equipment
Verified all pipe dimensions and pipe fittings
Documented all pressure and flow readings at equipment
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Existing Calculations Identified critical areas (greatest head loss)
Created spreadsheets for problem areas
Interpreted results with present system (Ideal operating pressure: 106 psig)
Pipe Pipe Equiv. Friction Loss Section Accum.Item Size GPM Length Fitting Length Velocity (per 100 ft.) dP dP
(in.) (ft.) Qty. (ft.) (fps) (ft.) (ft.) (ft.)PCW Return 4 245 5 1 6.404 4.059 0.2029 208.5385
Ball Valve 4 245 1 2.5 6.404 4.059 0.1015 208.6400
PCW Return 2 245 1 1 25.617 103.003 1.0300 209.6700
Union 2 245 1 0.45 25.617 103.003 0.4635 210.1335
90° Elbow 2 245 1 12 25.617 103.003 12.3603 222.4938
PCW Return 2 245 1 1 25.617 103.003 1.0300 223.5238
Pumps 2 245 1 25.617 103.003 0.0000 223.5238
+10 % SAFETY FACTOR 245.8762
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Existing Suggestions Evaluated critical friction losses
Manipulated pipe diameters on spreadsheet
Suggestions were made to save head loss
Example: Existing LPL tool #34 has 260.7 ft. of head loss (112.8 psig). With suggestions the updated system will have 180.9 ft. of head loss (78.3 psig). This suggestion will save 79.8 ft. of head loss (34.5 psig).
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Problems to be Solved Losing 21 psig (102-81 psig) across filters
Discrepancy of 16 psig between the pressure gauges and the controls system
In bay 11 - equipment would occasionally shut down during operation
Cracked 45° elbow on riser 11
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Solutions Pressure analysis performed, controls –calibration issue
After recalibration pump supply went from 102 psig to 86 psig
In bay 11 – there was not enough pressure at the equipment and pump output pressure was increased
The cracked 45° elbow on riser 11, will be replaced during the next shutdown
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New Design 250 GPM 330 GPM
Existing system HL = 302.4 ft. (130.9 psig) requiring 65 HP
Existing pumps will not handle flow increase
Existing heat exchanger must be modified/replaced
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New Pipe Routes Four different options for main headers
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Proposals Two main 4” headers off 5” SS Main
Filters to be moved to accommodate new header design
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Proposals (continued) 28 Plates to be added to the Heat Exchangers (65-93)
Pumps and motors on VFD to be replaced
Automatic air vents to be installed on all risers
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New Calculations Incorporated new flows, piping and fittings
Assigned new critical equipment
New operating pressure: 95 psig (42 HP)
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Pipe Pipe Equiv. Friction Loss Section Accum.Item Size GPM Length Fitting Length Velocity (per 100 ft.) dP dP
(in.) (ft.) Qty. (ft.) (fps) (ft.) (ft.) (ft.)
PCW Return 5 330 5 1 5.521 2.488 0.1244 193.7651
Ball Valve 5 330 1 3.1 5.521 2.488 0.0771 193.8422
PCW Return 5 330 1 1 5.521 2.488 0.0249 193.8671
Union 5 330 1 0.65 5.521 2.488 0.0162 193.8833
90° Elbow 5 330 1 15 5.521 2.488 0.3732
Suction Diffuser 5X4 330 1 1.850 1.8500 195.7333
PCW Return 4 330 1 1 8.626 7.046 0.0705 195.8037
Pumps 4 330 1 8.626 7.046 0.0000 195.8037
+10 % SAFETY FACTOR 215.3841
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Selection Close coupled, stainless steel 40 HP pumps
Heat exchangers to be upgraded to 93 plates and reconditioned
Stainless steel suction diffuser and triple duty valves
Relocation of filter housings with 20 micron filters to be installed
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Thank you!
Questions?
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