Reciprocating Compressor Installation and Validation MSD I 11452

Reciprocating Compressor Installation and Validation MSD I - 11452 • • John Blamer – Team Leader Promit Bagchi Elliot Kendall Matthias Purvis

» Agenda l l l l l Background – 2 min. Project scope – 2 min. Deliverables – 2 min. Customer Needs – 3 min. Objective Tree - 3 min. Engineering Specifications – 2 min. House of Quality – 2 min. Ranked Engineering Specs – 2 min. IPO (Input-Process-Output) – 4 min. Installation – 8 min. l l l Concept Selection – 20 min. l l Delivery Completed Tasks & Current state Tasks to be Completed Checklists Vibration Reduction § Mount Method, Adapter Plate § Calculations Coolant System § Calculations Risk Assessment – 4 min. Future Plan - 4 min.

» Background • Continuation of SD group P 09452 • Reciprocating Compressor donated to RIT by Dresser-Rand • To be installed in Machine Shop • For Research and Educational purposes • P 09452 did significant preparation work • Shipped from D-R facility in India • Should arrive in Port of New York on October 25 th • Trucked to Boulter Rigging -> RIT

» Project Scope • Understand compressor • Basic operation • Hardware • Understand installation needs • Vibration isolation • Cooling system • After install, focus on education and Beginning of Life characterization

» Deliverables l l Have the reciprocating compressor fully functioning by the end of Fall quarter Implement a preliminary DAQ system already owned by RIT Measure/document beginning of life characterization data for the compressor Review, test, and validate the Thermodynamics and Vibration labs created by P 09452

» Customer Needs

» Objective Tree Installation: Safe and proper installation. Mission Statement: To install and validate the performance of the compressor donated to RIT by Dresser-Rand. Laboratory procedures need to be developed and tested for educational purposes. Additionally, beginning of life characterization of compressor performance needs to be measured and documented for failure diagnostic research purposes. Validation: The baseline performance of the compressor must be characterized and compared with specifications. Obtaining Data: Must have an adequate DAQ system. Education: Student labs must be complete and thoroughly tested.

» Objective Tree Must be properly installed to begin testing ASAP. Room must be clean/organized to ensure safety and efficiency. Mission Statement: To install and validate the performance of the compressor donated to RIT by Dresser-Rand. Laboratory procedures need to be developed and tested for educational purposes. Additionally, beginning of life characterization of compressor performance needs to be measured and documented for failure diagnostic research purposes. Installation Safe and proper installation. Building structure must be capable of supporting weight of the compressor and accessories to avoid structural damage. Dampers must reduce vibrations to prevent excess noise and vibration transmission to the surrounding structure/rooms. Validation Coolant loop must be functional to prevent overheating. Obtaining Data Education Discharge air must be vented if necessary to prevent the room from getting too hot.

» Objective Tree Installation Mission Statement: To install and validate the performance of the compressor donated to RIT by Dresser-Rand. Laboratory procedures need to be developed and tested for educational purposes. Additionally, beginning of life characterization of compressor performance needs to be measured and documented for failure diagnostic research purposes Measure and document pressure, temp. , vibration, and operational characteristics over life of unit. Validation: The baseline performance of the compressor must be characterized and compared with specifications. Obtaining Data. Education Verify D-R provided specs with our own baseline readings.

» Objective Tree Installation. Must obtain DAQ hardware. Attempt to obtain system already owned by RIT rather than purchasing new. Mission Statement: To install and validate the performance of the compressor donated to RIT by Dresser-Rand. Laboratory procedures need to be developed and tested for educational purposes. Additionally, beginning of life characterization of compressor performance needs to be measured and documented for failure diagnostic research purposes Validation Obtaining Data: Must have an adequate DAQ system. All possible sensors should be utilized to facilitate any potential evaluations or tests. Assess DAQ system capabilities, and requirements. Upgrade as necessary. Education

» Objective Tree Installation. Existing lab procedures must be revised to ensure that they are feasible and up to date. Validation Mission Statement: To install and validate the performance of the compressor donated to RIT by Dresser-Rand. Laboratory procedures need to be developed and tested for educational purposes. Additionally, beginning of life characterization of compressor performance needs to be measured and documented for failure diagnostic research purposes Obtaining Data Labs need to be thoroughly tested by us so the time required and procedure can be verified. Labs must be tested on a group of students to ensure that an appropriate skill level is demanded. Education: Student labs must be complete and thoroughly tested. Procedures must be finalized to remove any remaining bugs.

» Engineering Specs Engineering Spec. Derives from Customer Needs Relative Importance (-, 1, 3, 9) Description Measure of Performance Engineering Predicted Value Units True Value ES 1 CN 3, CN 4, CN 8 1 Inlet Pressure Ambient Pressure (Psi) 14. 7 TBD ES 2 CN 1, CN 3, CN 4, 9 CN 6, CN 8, Outlet Discharge Pressure at the outlet discharge (Psi) Depends on Back Pressure Valve Bought TBD ES 3 CN 3, CN 4, CN 6, 9 CN 8 Outlet Discharge Temperature at the Discharge (F) Depends of Back Pressure Valve Bought TBD ES 4 CN 1, CN 3, CN 4, 9 CN 6, CN 8 Coolant Supply Temperature entering the compressor (F) 80 TBD ES 5 CN 1, CN 3, CN 4, 9 CN 6, CN 8 Coolant Return Temperature leaving the compressor (F) 90 TBD ES 6 CN 3, CN 4 Total Compressor BHP Horse-power of compressor (HP) 7 TBD ES 7 CN 3, CN 4, CN 8 3 Operating Speed Crankshaft Revolution of piston in cylinder (RPM) 500 TBD ES 8 CN 1, CN 3, CN 4, 9 CN 6, CN 8 Spring Constant, K The spring constant needed to minimize vibrations of system (lb. /in) Axial=1900, Lateral=1000 Transmissibility should be less than 1. TBD ES 9 CN 3, CN 4 Noise Sound level heard outside of the test cell (d. B) 73. 8 TBD ES 10 CN 3, CN 4, CN 6, 9 CN 8 Flow Rate Discharge flow rate at outlet (CFM) 32 TBD ES 11 CN 1, CN 7 9 Number of Needed Safety Equipment Proper amount of safety glasses, warning signs, (#) etc. Maximum occupancy = 10~ TBD ES 12 CN 1, CN 5, CN 7 1 Level of Cleanliness 1 = Dirty, 9 = Clean (Scaled) Between 7 -9 TBD ES 13 CN 2, CN 7, CN 8 9 Level of clarity for instructions when operating compressor 1 = Difficult for students to follow, 9 = Easy for (Scaled) students to follow Between 8 -9 TBD 9 3

» House of Quality 1 3 1 Noise 9 9 Inlet pressure Level of Cleanliness Operating Speed Number of Needed Saftey Equipment 1 Coolant Return Temperature 9 3 1 1 9 9 3 9 1 3 3 9 1 9 9 9 3 9 3 3 9 1 3 3 1 x(# of eyewear/gloves) ~ 10 x(# of warnings signs) ~ TBD 9 x(°F) ~ 90 9 x(°F) ~ 80 9 x(RPM) ~ 500 Predicted/Target Values 9 9 8(Clear) < x < 9(Very Clear) 9 x(lb/in) ~ Transmissibility < 1 9 x(psi) ~ TBD 9 x(CFM) ~ 32 x(°F) ~ TBD 9 x(d. B) ~ 73. 8 9 x(psi) ~ 14. 7 9 7(Fairly Clean) < x < 9 (Clean) 9 x(HP) ~ 7 Fully functional compressor by the end of SD 1 Create simply easy-to-use guide Beginning of life characterization of compressor performance for diagnostic research Compare baseline data with provided specifications Clean, organize, professional looking room Implement an exisiting DAQ system from RIT Safety Eductional: Labs (Termodynamics & Vibrations) Coolant Supply Temperature Customer Requirements Level of Clarity when Operating the Compressor Spring Constant Total Compressor BHP Outlet Discharge Pressure Output Flow Rate Outlet Discharge. Temperature Customer Weight Engineering Metrics Raw Score 270 225 162 144 135 117 108 45 21 9 Relative Weight 22. 33% 18. 61% 13. 40% 11. 91% 11. 17% 9. 68% 8. 93% 3. 72% 1. 74% 0. 74% Rank of Importance 1 st 2 nd 3 rd 4 th 5 th 6 th 7 th 8 th 9 th 10 th

f. C lo Le ve be r of ise No ur e ss s es t en ni n re tp ea Cl le of In el re re tu qu ip m y. E ra pe Te m fte Sa Le v ed ed Ne n tu ra pe ed pe g. S in at r an t HP es so pr m Co y. T em pl ur et an t. R ol Co he Op er gt on st g. C rin Sp r. B es so re te Ra es su Pr w e ur at pe r Flo e pr m Co up t. S an ol al in er at Op Co n he yw m Nu rit la To t rg isc ha t. D tle pu t Ou em e. T rg isc ha t. D Ou tle Ou Relative Weight » Ranked Engineering Specs 0, 25 Engineering Specification Importance 0, 2 0, 15 0, 1 0, 05 0

» IPO (Input, Process, Output) – Broad Overview Outputs Inputs Ease of use Customer Needs Process Validation tests Delivery DAQ system Implementation Beginning of life characteristics Fully functional compressor Installation Education

» IPO (Input, Process, Output) – Detailed View Outputs Inputs Ease of use Customer Needs Dr. Kolodziej Dr. Hensel Dresser-Rand Process User Manual Validation tests RIT faculty Boulter Delivery Beginning of life characteristics Fully functional compressor DAQ system Implementation Failure Diagnostics Installation Vibrations Lab E-Stops & Electricity Attach dampers to unit & bolt to floor Lattice dampers Electrician LORD Corp. System Analysis & Research Review & validate previous project Education Cooling System In-Class Uses RIT FMS Assignments Demonstration/Discussion Thermal Fluids Lab Future Labs

» Installation – Delivery Plan l l l Work with Boulter Rigging Dresser-Rand → Boulter Rigging → RIT 45’ of transportation through Building 09 l l Ensure a clear path Load must be distributed over 60 ft 2 using skates

» Installation – Completed Tasks » HVAC - Installed • Supply Ductwork • Exhaust » Electrical Components - Installed • • Supply Box E-Stop Button Electrical Receptacles on each wall Light Switches » Coolant System – Installed • U-Tube Heat Exchanger • Chilled Water Supply & Return » Delivery Preparation - Complete • Entrance Path Selected • Structural Reinforcement

» Installation – Current State » Ventilation » U-Tube Heat Exchanger » Electrical

» Installation – Tasks to be Completed » Vibration Isolation System • Finalize mounting system design. » Coolant System • • Coolant System Design Finalization Acquire and Install: • Pump • Piping • Reservoir • Heating Element • Thermostatic Valve • Flow Control Valve

» Installation - Checklists » Pre-Arrival Checklist ˃ ˃ Order cooling system components and hardware Fabricate damper adapter plates Contact Boulter to verify delivery procedures and schedule Contact and verify past PE work » Post-Arrival Checklist ˃ ˃ Drill mounting holes in skid Thorough visual inspection for damages or abnormalities Cooling system installation Verify compressor specs (hp, discharge psi, etc. )

» Concept Selection – Vibration Isolation Primary Options Option 1: Bolt unit directly to floor Option 2: Place directly on floor Compressor Frame Shop Floor Bolt Option 3: Place unit on concrete slab and rubber mat Option 4/5: Mount to vibration dampers Compressor Frame Concrete Slab Shop Floor Rubber Mat Shop Floor Vibration Mounts Bolt

» Concept Selection – Vibration Isolation Secondary Options Option 6: Shock and Spring Option 7: Recycled Tire Mounts Compressor Frame Shop Floor Option 8: Auto Motor Mounts Option 9: Hockey Pucks Compressor Frame Shop Floor

» Concept Selection - Vibration Isolation 1 2 3 Place on top of (Reference) Place on cement slab and Bolt directly floor, no rubber mat – no Weights to floor bolts Criteria Dampen vibrations transmitted to floor Clear building structure in basement 4 Mount to LORD vibration dampers Concepts 5 6 7 8 SLM Machinery Mount with Recycled Tire Auto Motor Mounts shocks/springs Mounts 9 Hockey Pucks 9 0 -1 1 1 1 1 0 0 -1 1 0 1 Secure compressor to floor 9 0 -1 -1 0 0 0 -1 Easy to install 1 0 -1 -1 -1 1 Durability of Unit 3 0 -1 1 1 Reduce Noise 3 0 -1 1 1 Relatively Low Cost Support Weight of Compressor 3 0 1 -1 -1 1 1 0 1 1 9 0 0 0 0 -1 -1 Sum +'s 0 3 4 4 3 3 5 4 5 Sum 0's 8 1 2 3 3 2 2 1 1 Sum -'s 0 3 2 1 2 2 1 3 2 Net Score 0 -19 4 17 11 10 10 -1 -1 Rank 7 8 5 1 2 3 4 5 6 No No No Yes No No No Continue? Primary Options Secondary Options Preferred Method

» Installation - Transmissibility Calculations

» Installation - Vibration Isolation Calculations Equations

» Concept Selection – Mount Adapter Plate for LORD dampers Bolt adapter plate to I-Beam Web Bolt holes to floor Bolt adapter plate to damper

» Concept Selection – Mount Adapter Plate for LORD dampers Compressor Frame Adapter Plate LORD Damper To be drilled and bolted to frame

» Concept Selection – Cooling System Layout #1: Immersion Heater

» Concept Selection – Cooling System » Layout #2: No Heater

» Concept Selection – Cooling System » Layout #3: Heater Wrap

» Concept Selection – Cooling System » Layout #4: In-Line Heater

» Concept Selection – Cooling System Concepts Criteria Weights Immersion Heater Wrap No Heater (Reference) In Line Heater Ability to heat cooling water to 80ºF 9 Time req'd to heat volume of water to 80ºF 9 1 0 -1 1 0 0 1 0 Price Durability 3 3 -1 -1 -1 1 0 0 -1 -1 Easy to install 1 0 -1 Sum +'s Sum 0's Sum -'s 1 2 2 2 0 5 0 1 1 3 Net Score Rank 3 1 -1 3 0 4 2 2 Continue? Yes In Line Heater No Heater Immersion Heater Net Score No No Yes

» Component Selection – Heating Element 45 Time Required to Heat Reservoir 40 35 Time (minutes) 30 25 20 15 10 5 0 0 200 400 600 800 1000 1200 Wattage of Immersion Heater Assumptions: • 10 degrees temperature rise • Four gallon reservoir 1400 1600 1800

» Installation – Cooling System Calculations

» Concept Selection– Cooling System Criteria Weight Copper Stainless Steel PVC Low head loss 6 0 -1 0 1 Inexpensive 9 -1 0 Easy to install 6 0 0 0 1 Durability of Unit 6 0 0 -1 -1 Sum +'s 0 0 1 2 Sum 0's 3 4 1 1 Sum -'s 0 0 1 1 Net Score -9 -6 3 6 Rank 3 3 2 1 Flexible Plastic Copper Flexible Plastic

» Installation – Cooling System Calculations

» Component Selection – Cooling System • ¾” Silicone Tubing • Pump • 3 way Thermostatic Valve

» Risk Assessment

» Risk Assessment Risk Item Effect Arrival of The entire project critical schedule will be set components is back. delayed Injury from moving components occurs Cause Design may not be finalized on time, a component could be overlooked, or the supplier may not be able to get the part to us soon enough. Broken hand or fingers. Failure to properly lock the shaft during maintenace or keeping hands free from moving componets Likelihood Severity (1, 3, 9) Importance (L*S) Action to Minimize Risk 3 9 27 Make sure that the design is complete and correct, and order parts as early as possible. 3 9 27 Warning signs, cautions in user manual, and guards in place if necessary

» Future Task Plans

» Future Task Plans

» Questions?