Reciprocating Compressor Installation and Validation

MSD I - 11452

• John Blamer – Team Leader • Promit Bagchi • Elliot Kendall • Matthias Purvis

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. Delivery

Completed Tasks & Current state

Tasks to be Completed

Checklists

Concept Selection – 20 min. Vibration Reduction

Mount Method, Adapter Plate

Calculations

Coolant System

Calculations

Risk Assessment – 4 min.

Future Plan - 4 min.

» Agenda

» Background

• Continuation of SD group P09452

• Reciprocating Compressor donated to RIT by Dresser-Rand

• To be installed in Machine Shop

• For Research and Educational purposes

• P09452 did significant preparation work

• Shipped from D-R facility in India

• Should arrive in Port of New York on October 25th

• 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

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 P09452

» Customer Needs

» Objective Tree

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.

Obtaining Data:

Must have an adequate DAQ system.

Validation:

The baseline performance of the compressor must be characterized and compared with

specifications.

Education:

Student labs must be complete and thoroughly tested.

» Objective Tree

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.

Must be properly installed to begin testing ASAP.

Dampers must reduce vibrations to prevent excess noise and vibration transmission to the surrounding structure/rooms.

Coolant loop must be functional to prevent overheating.

Building structure must be capable of supporting weight of the compressor and accessories to avoid structural damage.

Discharge air must be vented if necessary to prevent the room from getting too hot.

Room must be clean/organized to ensure safety and efficiency.

Obtaining Data

Validation

Education

» Objective Tree

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

Obtaining Data.

Validation: The baseline performance of the compressor

must be characterized and compared with specifications.

Measure and document pressure, temp., vibration, and operational characteristics over

life of unit.

Verify D-R provided specs with our own baseline readings.

Education

» Objective Tree

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.

Obtaining Data:

Must have an adequate DAQ system.

Must obtain DAQ hardware . Attempt to obtain system already owned by RIT rather than

purchasing new.

Assess DAQ system capabilities, and requirements. Upgrade as necessary.

All possible sensors should be utilized to facilitate any potential evaluations or tests.

Validation

Education

» Objective Tree

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.

Obtaining Data

Validation

Education: Student labs must be complete and thoroughly tested.

Existing lab procedures must be revised to ensure that they are feasible and up to date.

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.

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

Units Predicted Value True Value

ES1 CN3, CN4, CN8 1 Inlet Pressure Ambient Pressure (Psi) 14.7 TBD

ES2 CN1, CN3, CN4, CN6, CN8,

9 Outlet Discharge Pressure

Pressure at the outlet discharge (Psi) Depends on Back Pressure Valve Bought

TBD

ES3 CN3, CN4, CN6, CN8

9 Outlet Discharge Temperature

Temperature at the Discharge (F) Depends of Back Pressure Valve Bought

TBD

ES4 CN1, CN3, CN4, CN6, CN8

9 Coolant Supply Temperature

Temperature entering the compressor (F) 80 TBD

ES5 CN1, CN3, CN4, CN6, CN8

9 Coolant Return Temperature

Temperature leaving the compressor (F) 90 TBD

ES6 CN3, CN4 9 Total Compressor BHP Horse-power of compressor (HP) 7 TBD

ES7 CN3, CN4, CN8 3 Operating Speed Crankshaft Revolution of piston in cylinder (RPM) 500 TBD

ES8 CN1, CN3, CN4, CN6, CN8

9 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

ES9 CN3, CN4 3 Noise Sound level heard outside of the test cell (dB) 73.8 TBD

ES10 CN3, CN4, CN6, CN8

9 Flow Rate Discharge flow rate at outlet (CFM) 32 TBD

ES11 CN1, CN7 9 Number of Needed Safety Equipment

Proper amount of safety glasses, warning signs, etc.

(#) Maximum occupancy = 10~

TBD

ES12 CN1, CN5, CN7 1 Level of Cleanliness 1 = Dirty, 9 = Clean (Scaled) Between 7-9 TBD

ES13 CN2, CN7, CN8 9

Level of clarity for instructions when operating compressor

1 = Difficult for students to follow, 9 = Easy for students to follow

(Scaled) Between 8-9 TBD

Engineering Metrics

Customer Requirements

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ght

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ing

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Tem

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Fully functional compressor by the end of SD1 9 1 9 9 1 3 1

Create simply easy-to-use guide 3 9 Beginning of life characterization of compressor performance for diagnostic research 9 9 9 3 9 1 3 3 1 1 Compare baseline data with provided specifications 9 9 9 9 9 3 9 3 1

Clean, organize, professional looking room 1 9

Implement an exisiting DAQ system from RIT 9 9 9 9 1 3

Safety 9 9 9 3

Eductional: Labs (Termodynamics & Vibrations) 3 9 9 9 9 9 9 9 9 1

Predicted/Target Values

x(°F

) ~

TBD

x(C

FM)

~ 3

2

x(p

si)

~ TB

D

x(H

P)

~ 7

x(lb

/in

) ~

Tran

smis

sib

ility

< 1

8(C

lear

) <

x <

9(V

ery

Cle

ar)

x(R

PM

) ~

50

0

x(°F

) ~

80

x(°F

) ~

90

x(#

of

eyew

ear/

glo

ves)

~ 1

0

x(#

of

war

nin

gs s

ign

s) ~

TB

D

7(F

airl

y C

lean

) <

x <

9 (

Cle

an)

x(p

si)

~ 1

4.7

x(d

B)

~ 7

3.8

Raw Score 270 270 225 162 144 135 135 117 117 108 45 21 9

Relative Weight 22.33% 22.33% 18.61% 13.40% 11.91% 11.17% 11.17% 9.68% 9.68% 8.93% 3.72% 1.74% 0.74%

Rank of Importance 1st 1st 2nd 3rd 4th 5th 5th 6th 6th 7th 8th 9th 10th

» House of Quality

0

0.05

0.1

0.15

0.2

0.25R

ela

tive

We

igh

t

Engineering Specification Importance

» Ranked Engineering Specs

Process

Customer Needs

Education

Installation

Delivery

Validation tests

Ease of use

Fully functional compressor

Beginning of life characteristics

DAQ system Implementation

» IPO (Input, Process, Output) – Broad Overview

Outputs Inputs

Inputs

Process

Outputs

Customer Needs

Education

Vibrations Lab

Installation

Delivery

Electrician

Validation tests

Dr. Kolodziej

RIT faculty Dresser-Rand

Dr. Hensel

Lattice dampers

RIT FMS

Boulter

Ease of use

Fully functional compressor

User Manual

Attach dampers to unit & bolt to floor

Cooling System

E-Stops & Electricity

LORD Corp.

Thermal Fluids Lab

System Analysis & Research

Review & validate previous project

Beginning of life characteristics

In-Class Uses

Assignments Demonstration/Discussion

DAQ system Implementation

Failure Diagnostics

Future Labs

» IPO (Input, Process, Output) – Detailed View

Work with Boulter Rigging

Dresser-Rand → Boulter Rigging → RIT

45’ of transportation through Building 09

Ensure a clear path

Load must be distributed over 60ft2 using skates

» Installation – Delivery Plan

» 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 – Completed Tasks

» Ventilation » Electrical

» U-Tube Heat Exchanger

» Installation – Current State

» Coolant System • Coolant System Design Finalization • Acquire and Install:

• Pump • Piping • Reservoir • Heating Element • Thermostatic Valve • Flow Control Valve

» Vibration Isolation System • Finalize mounting system design.

» Installation – Tasks to be Completed

» 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.)

» Installation - Checklists

Shop Floor

Compressor Frame

Option 1: Bolt unit directly to floor

Bolt

Shop Floor

Compressor Frame

Option 2: Place directly on floor

Concrete Slab

Rubber Mat

Shop Floor

Compressor Frame

Option 3: Place unit on concrete slab and rubber mat

Vibration Mounts

Shop Floor

Compressor Frame

Option 4/5: Mount to vibration dampers

Bolt

» Concept Selection – Vibration Isolation Primary Options

Shop Floor

Compressor Frame

Shop Floor

Compressor Frame

Shop Floor

Compressor Frame

Shop Floor

Compressor Frame

Option 6: Shock and Spring Option 7: Recycled Tire Mounts

Option 8: Auto Motor Mounts Option 9: Hockey Pucks

» Concept Selection – Vibration Isolation Secondary Options

» Concept Selection - Vibration Isolation

Concepts 1 2 3 4 5 6 7 8 9

Criteria Weights

(Reference) Bolt directly

to floor

Place on floor, no

bolts

Place on top of cement slab and rubber mat – no

bolts

Mount to LORD

vibration dampers

SLM Machinery

Mounts Mount with

shocks/springs Recycled Tire

Mounts Auto Motor

Mounts Hockey Pucks

Dampen vibrations transmitted to floor 9 0 -1 1 1 1 1 1 1 1

Clear building structure in basement 1 0 1 1 0 0 -1 1 0 1

Secure compressor to floor 9 0 -1 -1 0 0 0 -1 -1 -1

Easy to install 1 0 1 0 -1 -1 -1 0 -1 1

Durability of Unit 3 0 -1 1 1 1 1 1 1 0

Reduce Noise 3 0 -1 1 1 1 1 1 1 1

Relatively Low Cost 3 0 1 -1 1 -1 -1 1 1 1

Support Weight of Compressor 9 0 0 0 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

Continue? No No No Yes No No No No No

Primary Options

Secondary Options

Preferred Method

» Installation - Transmissibility Calculations

𝑇. 𝑅. = 𝐹𝑇

𝐹0=

1 + (2𝜁𝑟)2

(1 − 𝑟2)2+(2𝜁𝑟)2

1/2

𝜁 =𝑐

2𝑚𝜔𝑛 𝑟 =

𝜔𝑑

𝜔𝑛 𝜔𝑛 =

𝑘

𝑚

𝑘𝑣𝑒𝑟𝑡𝑖𝑐𝑎𝑙 = 2000 𝑙𝑏/𝑖𝑛

𝑘𝑓𝑜𝑟𝑒−𝑎𝑓𝑡 = 1000 𝑙𝑏/𝑖𝑛

𝑘𝑙𝑎𝑡𝑒𝑟𝑎𝑙 = 1000 𝑙𝑏/𝑖𝑛

Equations

» Installation - Vibration Isolation Calculations

» Concept Selection – Mount Adapter Plate for LORD dampers

I-Beam Web

Bolt holes to floor Bolt adapter

plate to damper

Bolt adapter plate to I-Beam

» Concept Selection – Mount Adapter Plate for LORD dampers

Adapter Plate

Compressor Frame

LORD Damper

To be drilled and bolted to frame

Layout #1: Immersion Heater

» Concept Selection – Cooling System

Immersion Heater

» Layout #2: No Heater

» Concept Selection – Cooling System

» Layout #3:Heater Wrap

» Concept Selection – Cooling System

Heater Wrap

» Layout #4: In-Line Heater

» Concept Selection – Cooling System

In-Line Heater

Concepts

Criteria Weights Immersion Heater Heater Wrap No Heater (Reference) In Line Heater

Ability to heat cooling water to 80ºF 9 1 -1 0 1

Time req'd to heat volume of water to 80ºF 9 0 1 0 0

Price 3 -1 -1 0 -1

Durability 3 -1 1 0 -1

Easy to install 1 0 -1 0 -1

Sum +'s 1 2 0 1

Sum 0's 2 0 5 1

Sum -'s 2 2 0 3

Net Score 3 -1 0 2

Rank 1 3 4 2

Continue? Yes No No Yes

» Concept Selection – Cooling System

-2 -1 0 1 2 3 4

Heater Wrap

Immersion Heater

In Line Heater

No Heater

Net Score

0

5

10

15

20

25

30

35

40

45

0 200 400 600 800 1000 1200 1400 1600 1800

Tim

e (

min

ute

s)

Wattage of Immersion Heater

Time Required to Heat Reservoir

Assumptions: • 10 degrees temperature rise • Four gallon reservoir

» Component Selection – Heating Element

» Installation – Cooling System Calculations

-10 -5 0 5 10

PVC

Stainless Steel

Criteria Weight Copper Stainless Steel PVC Flexible Plastic

Low head loss 6 0 -1 0 1

Inexpensive 9 -1 0 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

» Concept Selection– Cooling System

Flexible Plastic

Copper

64

66

68

70

72

74

76

78

0.4 0.5 0.6 0.7 0.8 0.9 1 1.1 1.2 1.3

He

ad (

ft)

Pipe Diameter (in)

Head Vs. Pipe Diameter

copper

flexible plastic

pvc

stainless steel

$-

$2.00

$4.00

$6.00

$8.00

$10.00

Copper StainlessSteel

FlexiblePlastic

PVC

Pri

ce P

er

Foo

t

Pipe Pricing

» Installation – Cooling System Calculations

•¾” Silicone Tubing

•Pump

•3 way Thermostatic Valve

» Component Selection – Cooling System

0 3 6 9 12 15 18 21 24 27 30

Condensation buildup in the piston cylinder

Pressure ratio is elevated beyond an acceptable level

Noise level is higher than expected

Room is disorganized

A group member is unable to complete a critical part of the project

The building structure is unable to support the weight

Coolant loop does not adequately cool compressor

Vibration level is higher than expected

Insufficient funds and/or poor budgeting

Discharge air is dangerously hot

Injury from hot components occurs

Injury by electrocution occurs

DAQ system is not capable of measuring all necessary data

Arrival of critical components is delayed

Injury from moving components occurs

Importance (Likelihood*Severity) » Risk Assessment

» Risk Assessment

Risk Item Effect Cause Likelihood (1,3,9)

Severity (1,3,9)

Importance (L*S)

Action to Minimize Risk

Arrival of critical components is delayed

The entire project schedule will be set back.

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.

3 9 27 Make sure that the design is complete and correct, and order parts as early as possible.

Injury from moving components occurs

Broken hand or fingers. Failure to properly lock the shaft during maintenace or keeping hands free from moving componets

3 9 27 Warning signs, cautions in user manual, and guards in place if necessary

» Future Task Plans

» Future Task Plans

»Questions?