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A Modular Power Generation, Water Purification and Communications Disaster Response System

Harry O’Hanley 208 Argilla Rd

Ipswich, MA 01938

978 273 4867 hohanley@gmail.com

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1 Introduction To provide on-the-ground disaster response teams with power generation, water purification, and

communication capacity, an integrated equipment kit has been designed. The proposed design satisfies

all requirements of the Humanitarian Assistance and Disaster Relief Challenge, set forth by the

Department of Defense. It is recognized that previous kits have provided the required operational

capacity, but were too expensive and heavy for some partner organizations to deploy. Here, innovative

component selection allows the kit to remain within the monetary and weight budgets, while still

providing the required capacity. Fully self contained, all components fit within a Joint Modular

Intermodal Container and when necessary are individually packaged within protective casings.

In order to understand the design rational, it is first necessary to summarize the design requirements set

forth by the challenge organizers.

A) Integrated Kit 1) Fit inside a single Joint Modular Intermodal Container (JMIC)

2) Weigh less than 500 lbs (excluding container)

3) Include physical protection for components (such as protective Pelican cases)

4) Components capable of operating simultaneously using only the kit power supply

5) Components capable of operating independently or as an integrated kit

6) Comply with Occupational Safety & Health Administration (OSHA) safety requirements

B) Power Generation 1) Generate all power from renewable sources

2) Provide a constant 1KW for 24/7 operations

3) Regulated 12/24VDC and 110/220VAC outlets

4) Capable of integrating with external power supplies (mains, vehicles, etc)

C) Water Purification 1) Filter fresh and brackish water up to 15,000 ppm TDS

2) Produce 1,000 gallons per day of potable water

3) Disinfection procedure to maintain potable water at U.S. government standards

4) Product water must comply with EPA standards for safe drinking water.

D) Communications 1) Independent communication system for up to 20x users within a two mile radius

2) Capable of linking to local cell phone networks, if available.

3) Capable of linking to the internet

4) Capable of transmitting text, voice, photos and short/limited video.

2 Modules The three primary modules of the kit are Power Generation, Water Purification, and Communications.

The components of each system are described individually. A purchasing list is provided in Appendix A.

2.1 Power Generation The backbone of the kit, power generation capacity is essential to all other modules. Power can be

independently generated or the system can be connected to either AC or DC ground supplies.

Additionally, either 12/24 VDC or 120/240VAC can be output. This module is best understood by

considering the electricity generation, storage, and support components.

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2.1.1 Generation The kit independently generates electricity from wind and solar resources. This allows the user to

generate electricity in austere and undeveloped regions, without a dependence on fuels of any type. For

solar generation, Ascent Solar’s WaveSol Light 5-Meter BIPV Module was selected. This advanced

photovoltaic solar panel is manufactured on a flexible, lightweight plastic substrate, allowing the panel to

be rolled for transport. Each panel provides 140W, while weighing just 7.49 lbs. It is proposed that ten

of these solar panels be provided in the kit, providing 1400 W (1.4kW) of solar power generation

capacity. Each panel is about sixteen feet long and just over a foot wide. Because the solar panels are

printed on a flexible polymer backing, they can be rolled into a cylinder with less than a foot radius for

simple storage.

Figure 1: WaveSol Light 5-Meter Solar Module (Courtesy of Ascent Solar)

For wind generation, the Sunforce Marine Wind turbine was selected. This miniature wind turbine is

rated to produce 600W and weighs 35lbs. Two of these turbines are specified for the kit, providing a

cumulative 1200W (1.2kW) of wind power generation capacity. Moreover, designed for the marine

environment, this turbine is ruggedized to survive in difficult environments.

Figure 2: 600W Marine Wind Turbine (Courtesy of Sunforce)

While the challenge only requires 1kW of total continuous power generation, both the solar and wind

systems were specified the independently met this requirement because of potential resource

unavailability. Solar power is only available during the day. Conversely, wind resources can be available

both during the day and at night. The Sunforce wind turbine is capable of generating power in winds as

low as 4.5 mph. Therefore, by having excess specified solar and wind capacity, it is expected that the

1kV continuous power requirement will be met. During periods of excess generation, electricity can be

stored in the battery bank to supply the user with reserve electricity.

The solar panels can be rolled and stored directly in the JMIC. Per the manufacturers’ recommendation,

these modules do not require a hard case. The wind turbine blades can be dismounted from the turbine

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body for easy packaging in a Pelican 1450 Case. The turbines are directly strapped down in the JMIC

during shipping.

Table 1: Power Generation Component Specifications

Item Power

(kW)

Weight

(lbs) Cost Dimensions Quantity

Total

Power

(W)

Total

Weight

(lbs)

Total

Cost

Ascent Solar

WaveSol Light

5-Meter BIPV

Module

.14 7.49 $447

16.3’ L

1.18’ W

0.62’ Min

Bend Radius

10 1.4 74.9 $4470

Sunforce Marine

Wind Turbine 0.6 35 $765

27” L

25” W

9” D

2 1.2 70 $1530

Pelican 1450

Case ------- 5.51 $82

14.62” L

10.18” W

6.00” D

1 --------- 5.51 $82.00

Subtotal 2.6 150.1 $6082

2.1.2 Storage Electricity storage is essential to provide the user with reserve electricity during times of resource outage.

Additionally, an initial electricity supply can be used to immediately power components while the solar

panel and wind turbine arrays are initially deployed. Electricity storage is accomplished by a bank of 24V

lithium-ion batteries, manufactured by LithiumPro. Each battery provides 1.024 kWh, while weighing

only 20lbs (for comparison, a typical lead acid battery of similar capacity weighs 60lbs). A bank of eight

batteries provides 8.19 kWh of power reserve (in other words, 1kW of power for 8.19 hours). This

provides ample margin for the user to keep the operation powered if there is a temporary lack of solar or

wind resource.

To protect the batteries from debris and water, each is individually packaged in a hard plastic box. The

boxes can be arranged adjacent to each other, allowing all batteries to be utilized. Alternatively, the

batteries can be separated and used independently if needed.

Table 2: Electricity Storage Component Specifications

Item Capacity

(kWh)

Weight

(lbs) Cost Quantity

Total

Capacity

(kWh)

Total

Weight

(lbs)

Total

Cost

LithiumPro 24V

Powerpack 1.024 20 $1400 8 160 $11,200

Hard plastic

battery box -------- 1 $8.99 8 -------- 8 $71.92

Subtotal 168 $11,272

2.1.3 Components In order to satisfy the AC and DC input and output requirements, numerous components are required to

properly condition the electricity at various points in the system. For reference, the major components of

electrical system layout are illustrated in Figure 3. To understand the system, the components and their

operation will be detailed in a piecewise fashion, beginning with the different inputs.

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Electricity produced by the solar array is conditioned to 24VDC by an Outback Flexmax 80 Solar

Charge Controller and then supplied to the battery bank.

The wind turbines have internal charge controllers, which also supply 24VDC to the batteries.

The system accepts a local DC power supply (e.g. a vehicle) from anywhere between 10.8 – 28

VDC and a Samlex DC-DC Step Up Converter, conditions the supply to 24VDC, which is then

input to the battery bank.

Given a 120 or 240 VAC source, the system can either convert it to 24VDC to supply to the

battery bank through a Samlex AC Battery Charger. Alternatively, the AC can either be directly

used or, if necessary, transformed (120VAC to 240VAC and versa visa) through a Seven Star

Step Up/Step Down Transformer.

Electricity from the battery bank can be used in multiple manners:

24VDC can be directly supplied from the batteries.

The electricity can be converted to 12VDC through a Samlex DC-DC Down Converter.

The electricity can be inverted to 120VAC through a PowerBright Inverter. This supply can then

either be utilized or transformed to 240VAC, as detailed above.

Figure 3: High Level Electrical System Architecture

The electrical system is connected with ground fault indicators and fuses to prevent shock and overload

respectively. Additionally, industrial grade panel switches are used to direct electricity to the proper

component given the required input and output configuration (for clarity, these minor components have

been omitted from Figure 1. Per manufacturer recommendations, eight gauge wire is used for connecting

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the generation modules and twelve and twenty gauge wire is used for connecting the various components.

Finally, the entire electrical component system is packaged in a Pelican 1610 Case.

It is important to note that the specific make and model of components specified above are not required

and can be substituted for others, if more affordable or lighter weight items can be sourced. The

components specified here were determined to be the optimal and lowest priced at the time of writing.

However, this layout is mainly intended to demonstrate that the electrical requirements can in fact be met

with off-the-shelf electrical components.

Table 3: Electrical System Component Specifications

Item Relevant rating Weight

(lbs) Cost Quantity

Total

Weight

Total

Cost

Outback

Flexmax 80

Solar

Charge

Controller

24VDC output 12.2 1 $749 1 12.21 $667

Samlex DC-

DC Step Up

Converter

10.8 -28VDC

input

24VDC output

6 $1,294 1 6 $1,090

Samlex AC

Battery

Charger

120/240 VAC

input

24VDC output

12.12 $470 1 12.12 $470

Samlex DC-

DC Step

Down

Converter

24VDC input

12VDC output 1.5 $120 1 1.5 $120

Seven Star

Transformer

120/240VAC

input

120/240VAC

output

12 $75 1 12 $75

PowerBright

Inverter

24VDC input

120VAC output 11.5 $190 1 11.5 $190

Surface

Mount GFI 24VDC/240VAC 0.15 $62.76 1 0.15 $62.76

Switch, two-

way 24VDC/250VAC 0.12 $26.31 4 0.48 $105.24

Switch,

three-way 24VDC/250VAC 0.13 $28.85 3 0.29 $86.55

Pelican

1650 Case -------------------- 24.3 $195 1 24.3 $195

Subtotal 94.55 $2,807

2.2 Water Purification Water purification is achieved through a portable, combination reverse osmosis and ultraviolet system.

Manufactured by Aqua Sun, the Responder S system first channels source water through a 5.0 micron

sediment filter and then through a 0.5 micron polishing filter to remove chemicals and contaminants.

Finally, the water is exposed to an ultraviolet light, which kills bacteria, viruses and other microorganisms

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to a 99.999% purity, as cited by the manufacturer. All water contact components are NSF and FDA

approved.

Figure 4: Responder S Water Purification System (Courtesy of Aqua Sun)

The unit runs on a 12VDC electrical system, allowing it to integrate with the power generation module.

The over specified power generation module provides ample electricity for this system, while also

providing a 1kW output. In this configuration, the module is capable of producing one gallon of potable

water per minute. Discussions with the vendor confirmed that the system is capable of operating

continuously for twenty four hours per day, therefore yielding an output of 1,440 gallons of potable water

per day. Moreover, the system has its own integrated solar panel, allowing it to operate independently

from a power supply if needed. Water purification capacity drops approximately an order of magnitude

in this backup configuration and it is only intended to be an interim solution until components of the

power generation system can be brought online.

The entire unit is packaged by the manufacturer in a hard Pelican case and weighs 50 lbs.

Table 4: Water Purification Component Specifications

Item Capacity

(GPD) Dimensions

Electrical

Requirement

Weight

(lbs) Cost

Aqua Sun

Responder S 1440

22”Width

18” Length

10” Depth

12VDC 50 $1800

2.3 Communications The Communications Module provides capacity for independent team communication, connection to a

local cellular network, and global voice and data transmission. A ruggedized laptop is used for data

transmission and team coordination. These sub-modules draw upon ruggedized, proven components to

offer communication capability in an austere environment.

2.3.1 Independent Communication System Intra-team communication is accomplished through a network of Motorola APX 7000XE P25 Portable

Radios. Proven through first responder and maritime use, this ruggedized radio is specifically designed

for operation in extreme environments. With the capability to transmit in both the VHF and UHF

frequency ranges, the communication range is about three miles. Transmission encryption is possible,

which may prove important depending on the local security situation. Moreover, the radios have an

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integrated GPS module, allowing central monitoring and coordination of personnel. Each radio weighs

just less than one pound, has an eight hour battery life, and can be recharged via the Power Generation

Module. For protection during transit, the radios are stored in two Pelican 1470 Cases.

Table 5: Independent Radio Component Specifications

Item

Minimum

Range

(Miles)

Weight

(lbs) Dimensions Cost Quantity

Total

Weight

(lbs)

Total Cost

Motorola

APX

7000XE P25

Portable

Radio

3 1

6.94”Height

3.32” Width

1.64” Depth

$500

(estimated) 20 20

$10,000

(estimated)

Pelican 1470

Case ---------- 5.51

15.62”

Length

10.43”

Width

3.75”

Height

(Interior

Dimensions)

$99 2 11.02 $198

Subtotal 31.02 $10,198

(estimated)

2.3.2 Local Cellular Communication There are two mechanisms to connect to a local cellular network: a global GSM cell phone and a dual-

SIM card cell phone. AT&T is selected as the service provider for the GSM cell phone because of their

extensive global coverage through partnerships with local cellular networks, as seen in Figure 5. With a

GSM phone, the user will be able to instantly integrate with the local network. The Motorola Tundra

ruggedized cell phone is the recommended cell phone as it conforms to MIL-STD-810F, confirming its

ability to operate under conditions that include shock, vibration, rain, humidity, drop, blowing dust, low

temperatures, and high operating/storage temperatures.

Figure 5: Global AT&T and Partner Cellular Coverage (courtesy of CNET)1

1 CNET Review of Global Cellular Coverage. http://reviews.cnet.com/4520-3504_7-6253284-3.html

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Second, the Nokia C2 dual-SIM card is also provided in the kit. This cell phone allows the user to install

SIM cards from up to two local different local cellular networks. This allows a more direct connection to

the local networks and offers flexibility if one network is damaged or suffering an outage. Moreover, this

option provides cellular connection if the country where the user is deployed does integrate with AT&T

GSM coverage. Finally, this option provides the user with local phone numbers and text messages and

calls can be simultaneously sent and received via both SIM card numbers.

For a level of redundancy and to prevent a communication bottle neck, three of each type of phone are

included in the kit. The six cell phones are contained within two Pelican 1060 Micro Cases for protection

during transit.

Table 6: Cellular Component Specifications

Item Type Weight

(lbs) Dimensions Cost Quantity

Total

Weight

(lbs)

Total

Cost

Motorola

Tundra

Global

GSM 0.30

3.85”Height

2.1” Width

0.94” Depth

$200 3 .9 $600

Nokia C2 Dual-

SIM 0.16

4.25”

Height

1.77” Width

0.57” Depth

$55 3 0.48 $165

Pelican 1060

Micro Case ---------- 1

15.62”

Length

10.43”

Width

3.75”

Height

(Interior

Dimensions)

$30 2 2 $60

Subtotal 3.38 $825

2.3.3 Global Communication Two Iridium 9555 Satellite phone connects the user with voice and data transmission capability at any

point on the globe. When used for voice transmission, the unit operates like a normal phone. For data

transmission, the unit can be connected to a laptop computer. When acting as a modem, the phone can

transmit data at a rate of 10kbps. Each phone weighs only half a pound and therefore two units are

included in this system. This provides both a level of redundancy and the ability to simultaneous transmit

voice and data. To protect the phones during transit, each is packaged in a Pelican 1300 case.

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Table 7: Satellite Phone Component Specifications

Item Weight

(lbs) Dimensions Cost Quantity

Total

Weight

(lbs)

Total

Cost

Iridium 9555

Satellite

phone

0.56

5.62”Height

2.16” Width

1.18” Depth

$1100 2 1.12 2200

Pelican 1300

case 3.53

9.87" Height

7.00" Width

6.12" Depth

$80 2 7.06 $160

Subtotal 8.18 $2360

2.3.4 Computer System A Panasonic Toughbook 53 connects the communications systems and helps team management. The

ruggedized computer is intended to handle difficult environments. The satellite phone can be connected

to laptop, enabling the user to connect to the internet. Additionally, the laptop can be used to monitor the

location of team members via the radio mounted GPS systems. Contained within an integrated hard case

and shock resistant, the computer requires no additional packaging.

Table 8: Laptop Specifications

Item Weight

(lbs) Dimensions Cost

A Panasonic

Toughbook

53

5.6

11.1”Height

13.4” Width

2.2” Depth

$1750

2.4 System Summery The above detailed system meets all functional requirements set forth by the Department of Defense.

Highly modularized, the components can be set up to operate as a single entity or be separated and used

independently as deemed necessary. A complete cost and weight summery is presented in Table 9 below

(note: component purchasing information is presented in Appendix A). The total weight and cost of the

system (not including the JMIC) are 496.87 lbs and $27,348, respectively.

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Table 9: Component Summary

Component Quantity Total

Weight

Total

Cost

Power Generation

Ascent Solar WaveSol Light 5-Meter BIPV Module 10 74.9 $4470

Sunforce Marine Wind Turbine 2 70 $1530

LithiumPro 24V Powerpack 8 160 $11,200

Hard plastic battery box 8 8 $71.92

Outback Flexmax 80 Solar Charge Controller 1 12.21 $667

Samlex DC-DC Step Up Converter 1 6 $1,090

Samlex AC Battery Charger 1 12.12 $470

Samlex DC-DC Step Down Converter 1 1.5 $120

Seven Star Transformer 1 12 $75

PowerBright Inverter 1 11.5 $190

Surface Mount GFI 1 0.15 $62.76

Switch, two-way 4 0.48 $105.24

Switch, three-way 3 0.29 $86.55

Pelican 1650 Case 1 24.03 $195

Pelican 1450 Case 1 5.51 $82

Power Generation Subtotal 398.69 $20,415

Water Purification Aqua Sun Responder S 1 50 $1800

Water Purification Subtotal 50 $1800

Communications

Motorola APX 7000XE P25 Portable Radio

20 20 $10,000

(estimate)

Pelican 1470 Case 2 11.02 $198

Motorola Tundra 3 .9 $600

Nokia C2 3 0.48 $165

Pelican 1060 Micro Case 2 2 $60

Iridium 9555 Satellite phone 2 1.12 2200

Pelican 1300 case 2 7.06 $160

A Panasonic Toughbook 53 1 5.6 $1750

Communications Subtotal 48.18 $5,133

Total 496.87 $27,348

3 Conclusion This proposal outlines the components required to create a deployable, power generation, water purification, and communication kit. The items required to provide disaster responders with such basic infrastructure can be selected to fit within a JMIC and meet the weight and cost requirements set forth by the challenge seekers. It is not necessary to use the specific components selected here and equivalent substitutions can be made if weight and cost savings can be incurred. Here, the components proposed were the lowest cost and weight items available at the time of writing.

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It is recommended that a professional electrical engineering firm be referenced when performing the detailed design and fabrication of the electrical component system. It is important to properly connect, ground, and cool the electrical components to prevent system damage. If selected by the challenge seeker, the author would be interested in discussing plans to move this project forward. Further detailed design work can be performed to fabricate a proof of concept kit. The ability to actually prototype with components and assemble a kit will allow the intricate details of the system to be worked out. From there, deployment ready kits can be fabricated and supplied.

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Appendix A: Purchasing Information

Item Vendor Vendor Contact WaveSol Light 5-Meter BIPV Module Ascent Solar www.ascentsolar.com

Marine Wind Turbine Sunforce www.sunforceproducts.com

24V Powerpack LithiumPro www.lithiumpros.com

Outback Flexmax 80 Charge Controller altEStore www.altestore.com

Samlex DC-DC Step Up Converter Samlex www.samlexamerica.com

Samlex AC Battery Charger Samlex www.samlexamerica.com

Samlex DC-DC Step Down Converter Samlex www.samlexamerica.com

Transformer Seven Star www.sevenstar.com

Inverter Powerbright www.powerbright.com

Hard plastic battery box Mcmaster www.mcmaster.com

Surface Mount GFI Mcmaster www.mcmaster.com

Switch, two-way Mcmaster www.mcmaster.com

Switch, three-way Mcmaster www.mcmaster.com

Responder S Aqua Sun www.aqua-sun-intl.com

APX 7000XE P25 Portable Radio Motorola www.motorola.com

Motorola Tundra Motorola www.motorola.com

Nokia C2 Nokia www.nokia.com

A Panasonic Toughbook 53 Panasonic www.panasonic.com

Iridium 9555 Satellite phone Iridium www.iridium.com

Pelican 1060 Micro Case Pelican www.pelican.com

Pelican 1300 Case Pelican www.pelican.com

Pelican 1450 Case Pelican www.pelican.com

Pelican 1470 Case Pelican www.pelican.com

Pelican 1610 Case Pelican www.pelican.com