Company Sponsors Marybeth Radtke, Brandi Dittrich Faculty Advisors AME: Dr. Haider Hekiri ISE: Dr. Kash Barker
Christian Almonrode, Matthew Feisal, Andrew Nantze, Ian Wright Proof of Concept
• Paint booths release VOCs during maintenance operations and are captured in filtration system • Title V permit allows for 250 tons of VOC emissions across all Tinker AFB facilities • Data is captured manually and human error has led to the system running out of compliance • Goal is to eliminate human error in data reporting • New electronic system must be compatible with Honeywell Building Management System (BMS) • Handwritten logs and lack of timely notifications are likely cause of out-ofcompliance events • Systems needs to be robust with rapid ability to notify management
• Oklahoma City Air logistics Complex (OC-ALC) is the largest single-site employer in Oklahoma • 9,000-plus active duty and civilian employees • 8.2 million square feet • 76th Maintenance Group Environmental Engineering
• OC-ALC performs programmed depot maintenance on multiple weapons platforms • United States Air Force, Navy, Air Force Reserve Oklahoma Air National Guard • Title V Air Quality permit restricts the amount of Volatile Organic Compounds (VOCs) allowed to be emitted • Paint booths use negative pressure filtration systems to capture VOC emissions
System Cost
Fines
Pressure Gauge
Recurring Cost
• Budget: Efficient use of taxpayer dollars • Final cost will be dependent on Honeywell proposal
Projected Costs:
Findings:
Installation: $10,000 Monthly Maintenance: $2,000 Fines: -$10,000 per occurrence Current labor: $1,260 per year
Return on Investment: <1 year Net Positive: $7,200 each year after year 1 Savings over 10 years: $160,000
Filtration System
Microcontroller
• Physical simulated 3 stage filtration system
• Programmable Arduino • Connects gauge to database
• Actual transmitter proposed • Connected to dynamic pressure
Database
• Collect data from Arduino • Test output of data to Excel file
Evaluation of Current System Cost: • $10,000 fine per event • Costly administrative reporting of problems Effectiveness: • ± 2% mechanical accuracy • Pressure readings in inches of water column (inch w.c.) • Has run out of compliance Redundancy: • No secondary system • Only one data log per shift
Excel
• Generate pressure log reports • Identify and notify out-of-compliance events
Alternatives
Financial Statement
Monthly Maintenance
Paint Booth/Hangar Pressure Drop Electronic Monitoring Problem Definition
Company Background
Initial Installation
Tinker Air Force Base
Recommendations
Dwyer 605-3 - $258 • Identical to current gauge • Mechanical and electrical zeros are inseparable • Reads pressure, even if electrical system is down
Dwyer Compact Differential Pressure Transmitter provides the greatest improvement in responsiveness to out of compliance events
Honeywell Building Management System allows for system flexibility
• Minimal changes to current processes
• Automatically alert personnel via email and SMS
Dwyer MP-003 - $240 • Only a signal switcher • Wrong dial/face display
• ± 2.5 inch w.c. range
Dwyer 668B-16-1 - $129 • Cheapest option • Only a data transmitter • Could be added to current system with minimal changes in procedures Continue with current system • No additional cost incurred • Highest likelihood for fines to be levied
• ± 0.8% electronic accuracy • Magnehelic gauge reads pressure if electrical system is down
• Capture data every 5 minutes
• Install door sensors so database knows when system pressure increases
System Impacts • Easy access to database of information • Reduction of personnel and time • Potential use of historical data • More efficient use of filters • Predictable downtimes
• Reduce fines from out-of-compliance events • Lower environmental impact from air contaminates (less released) • Lower administrative action and expenses from problems