reciprocating compressor installation and...
TRANSCRIPT
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
Cu
sto
mer
Wei
ght
Ou
tlet
Dis
char
geTe
mp
erat
ure
Ou
tpu
t F
low
Rat
e
Ou
tlet
Dis
char
ge P
ress
ure
Tota
l Co
mp
ress
or
BH
P
Spri
ng
Co
nst
ant
Leve
l of
Cla
rity
wh
en O
per
atin
g th
e C
om
pre
sso
r
Op
erat
ing
Spee
d
Co
ola
nt
Sup
ply
Tem
per
atu
re
Co
ola
nt
Ret
urn
Tem
per
atu
re
Nu
mb
er o
f N
eed
ed S
afte
y Eq
uip
men
t
Leve
l of
Cle
anlin
ess
Inle
t p
ress
ure
No
ise
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?