Final Acoustic Enclosure Presentation
Final Acoustic Enclosure Presentation
Final Acoustic Enclosure Presentation
Acoustic enclosures
Problem statement
Optimum design of an acoustic enclosure for a diesel generator set (Ratings: 125 kVA) which satisfies the following clauses: The enclosure should act as a containerised portable vessel along with the generator set (DG set) feasible to be used for frequent mobile applications. Proper air ventilation for DG set should be available. Noise reduction achieved should be achieved as specified under the CPCB Norms.
Company Profile
heavy industrial fabrications, heavy duty storage racks, material handling pallets.
Customers :
DEUTZ ENGINES PVT. LTD, CUMMINS INDIA LTD, ASHOK LEYLAND LTD, FULL MARK MARKETING PVT LTD, SANDVIK ASIA, GODREJ & BOYCE MANUFACTURING CO. LTD, R & DE (E), PUNE, VRDE- AHMEDNAGAR.
Presentation details
Introduction Problem definition Result comparison
Structure design
Sound proofing
References
Results
Characteristics Regular enclosure Modified enclosure
Number of enclosure frame 2 parts : 1 enclosure and 1 parts base frame Weight
Lifting nodes
Variable
Air ventilation
6 mm of back pressure
Sound proofing
DESIGN PROCEDURE
MATERIAL SELECTION FOR FRAME
OPTIMIZATION PROCESS
Material selected is AISI 1020 Selecting ideal C/S of channels : Moment of resistance (strength) M = b * Z = b * (I/y) Consider various shapes of channel to calculate m.o.i : For hollow rectangular section, I = (BD3/12) (bd3/12) = ((100*1803)/12) ((92*1723)/12) = 95.8 * 105 mm4
For I section, Ixx = ((B*D3)/12)-((b*d3)/12) = ((100*1803)-(92*1803))/12 = 48600000-44712000 = 38.8*105 mm2 For C channel, By area method, Co-ordinates for centroid of section X = 25248/2112 = 11.95 Y = 90 So, I = 59.68*105 mm4
METHODOLOGY OF FEA
Discretize the continuum Select interpolation function Find the element properties Assemble the element properties to obtain the system equations Impose the boundary conditions Solve the system equations
Taking the genset load at predefined nodes and lifting supports at 4 end nodes of enclosure we can analyze the system for maximum and minimum stresses as follows:
OPTIMIZATION PROCESS
The sub-problem approximation method is used Max allowable stress is 84 MPa Maximum feasible and infeasible sets for iteration are chosen 100 and 80 respectively Quadratic curve fitting polynomial function is chosen for design and state variables for next iteration Design variable: 5 t 12.2 0 LOCX1 2000 State variable: 10 MAXSTRESS 84 Objective function: weight=dens *(2*B*t+2*(D2*t)*t*(4000*4+1600*6+2000*4)) Where, dens =density of AISI 1020 i.e. 7850 kg/m3
Design Optimization
From above analysis we obtain maximum stress in the entire structure as 53.511 MPa and the feasible nodes are for lifting are at a distance 482 mm from all base nodes. The optimum thickness value obtained is 6.2 mm. The analysed result obtained can be formulated on graph as follows:
OPTIMIZATION RESULT
referring to ISMC codes
6.4
152 x 76 (RSC)
17.88
6.4
127 x 64 (RSC)
14.9
AIR VENTILATION
Cross ventilation and fresh air is must for satisfactory operation of genset. Air should flow from alternator to engine end. As air flows through enclosure, its temperature increases. This increase is difference between temperature measured at alternator and at outdoor. The maximum allowed temperature rise is limited to 5oC to 10oC.
The Required air flow rate to keep specific temperature rise in control can be calculated as : ma =
where,
ma = mass flow rate of air into enclosure
Q = heat rejection into enclosure (25kW) Cp = specific heat (0.017 kW/C) T = temperature rise in enclosure (5 C) = density of air (1.099 kg/m3)
So, for T=5 o C, we require mass flow rate of air of about 4469.30 lit/sec. To allow this air flow in the enclosure, we need proper inlet and outlet openings without any compensation in soundproofing. Also, care has to be taken that, at high velocities of radiator fan, there should be no suction of rain water, dirt, debris or any other unwanted elements with the air . To achieve such opening, which allows only air to pass with minimum foreign particles LOUVERS are used.
A louver is a ventilation product that allows air to pass through it while keeping out unwanted elements
The basic consideration for louver section are : Free Area Water penetration Resistance to air flow
Fig.- Louver
Free area is derived by taking the total open area of a louver and dividing by the overall wall opening. Generally, it is taken as 35% to 60%.
Fig.- Free Area for Air Flow
First Point of Water Penetration is the point at which a louver allows the passage of water through the louver.
Every obstruction in the airstream creates resistance, which reduces velocity of air flow. The resistance of the louver can be measured by running air through the louver and measuring the pressure differential at various free area velocities. Lower blade angles or more aerodynamic shapes create less resistance.
For proper enclosure ventilation our objective is to select louver dimensions for both inlet and exit keeping in mind : The company standards Prescribed static pressure Louver considerations
Calculation procedure
Find louver free area Refer company standards and free area chart to get louver dimensions Find front inlet louver dimensions (1.5times the radiator core ) Find rear exit louver dimensions (2.5 to 3 times the radiator core)
Opening for inlet is done on either sides of enclosure as shown in the diagram
SOUND PROOFING
TARGET
Reduce the maximum sound power level of 97dB to 71 dB at distance of 1 meter from all sides of enclosure.
NOISE PREDICTION METHOD (theoretical) This method can predict level of noise with acceptable engineering accuracy over the frequency range 50-5,000 Hz using simple and readily available expressions. According to experiments performed by National Research Council (NRC) in Canada the difference between practical measurement and theoretical noise prediction is less than 0.5dB and 90% of results were found to lie within 2.5 dB.
F L O W C H A R T
&ALUMINIUM PLATE
a)Polyethylene foam ( Density = 36.84kg/m3) d) Rockwool ( Density = 36.84kg/m3)
Future scope
Study and development of optimization code by combining the following aspects for acoustic enclosure: Optimum Weld thickness to be used Computational fluid dynamics of flow of air through enclosure Thermo-structural analysis to study effective heat transfer around in the enclosure the DG set
Development of insertion loss model for acoustical treatment at the sound source. At present transmission losses of 25 dB have been achieved from the various acoustical materials applied to the enclosure body. But, additional sound reduction of up to 10 dB can be achieved using insertion loss phenomenon.
REFERENCES:
BOOKS Mechanical Engineering Design, by Joseph E. Shingley, Pg. 933, 983. Design of Machine Elements, by V. B. Bhandari, Pg. 1 to 82, 22 to 57, 71 to 85. Structural Design and Drawing, by N. Krishna Raju, Pg. 199 to 203. Structural Engineering for Architecture, by A. P. Dongre, Pg. 13.1 to 13.8. Statics and Strength of Material (Foundation for Structural Design), by Barry Onouye, Pg. 151to 261, 415. Mechanical Vibrations and Noise Engineering, by A. G. Ambekar, Pg. 343 to 384. JOURNALS Diesel Engines Technical Data, published on Aug 1998(Company Confidential). Reciprocating internal Combustion Engines (British Standard Controlled). Application Manual-Liquid Cooled Generator Sets (Company Confidential). Engine Installation Recommendation (Company Confidential).
PAPERS Optimal Design of an Enclosure for a Portable Generator, by Joseph E. Blanks. Development of Technique to Predict Level of Dynamic Noise of Hydraulic Excavators, by Mikio Iwasaki. Accuracy of Prediction Methods for Sound Transmission Loss, by K. O. Ballagh. SITES http://www.efunda.com/Materials/Alloys/carbon_steels/ show_carbon.cfm?ID=AISI_1020&prop=all&Page_Title=AISI %201020. http://www.conpargroup.co.uk/evenchan.htm http://www.engineersedge.com/beam_bending/beam_bending5.htm http://www.sail.co.in [email protected]
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