Cooling Loop Calculations &...

Student Version Operations and Maintenance Manual

Contact Sheet for P09452: Compressor Installation, Interface, and Education

First Name Last Major/Title Team Role Email Cell Phone

Snehapriya Rao ME Project Lead [email protected] 917-628-5839

Edward Budriss ME Individual Contributor [email protected] 267-210-6822

Alex Scarangella ME Individual Contributor [email protected] 914-806-6144

Edward Wolf CE Individual Contributor [email protected] 203-648-3155

Anna Cheung ISE Individual Contributor [email protected] 518-588-7375

Margaret Bailey ME/Professor (Endowed Chair) Guide [email protected] 585-475-2960

Marca Lam ME Professor Consultant [email protected] 585-475-6871

Lawrence Agbezuge ME Professor Consultant [email protected] 585-475-2157

John Wellin ME Professor Consultant [email protected] 585-475-5223

Amy Hortop ME Professor Consultant [email protected] 585-475-5628

Rizk SinadaCivil Instructor/

Project Manager RIT FMS

Consultant [email protected] 585-475-6716

Scott Wolcott CET ProfessorProfessional Engineer Consultant [email protected] 585-475-6647

Dave Hathaway ME Operations Manager Consultant [email protected] 585-475-2184

Dave Harris Director, Environmental Management Consultant [email protected] 585-475-2060

Jim Yarrington Director of FMS Consultant [email protected] 585-475-6932

Bobby Colon RIT Legal Counsel Consultant [email protected] 585-475-6932

mailto:[email protected]














Contact Sheet for P09452: Compressor Installation, Interface, and Education

First Name Last Major/Title Team Role Email Cell Phone

Scott Delmotte Manager Development Engineering

Contact (Painted Post) [email protected] 607-937-2113

Ray McKinney Condition Monitoring Specialist Contact (Olean) [email protected] 716-372-4340

Mike Bunce Direct of Recruiting Contact (Olean) [email protected] 716-375-4311

Terry McCarvillePCB PiezotronicsField Applications

EngineerConsultant/Sales [email protected]

John Kingham

GE Energy Optimization and

Control - Field Application Engineer

Consultant/Sales [email protected] 609-238-3535

Skip Morrison Regional Manager Consultant/Sales [email protected]

281-844-4685

Jason Vigil Professional Engineer, Jensen Engineering, PC Consultant [email protected] 585-482-8130

Willis Boulter Boulter Rigging Consultant [email protected] 585-261-3102









Calculations and Simulations

Cooling Loop Calculations & SpecificationsSome of the heat of compression is transferred through the cylinder wall into four water jacket channels. Each of these channels is identical. For the theoretical analysis of this transfer, these channels were approximated as being round. The exact dimensions of theses channels and other relevant geometries are unknown so approximate values were used and may be changed as more precise information becomes available. The following is a list of assumed dimensions and other parameters. The only value that is uncertain is the diameter; the assumption is based on the known result.

Description Value Unitdelta t in compressor 116.67 Kcircum 21.99 inchnumber of jackets 2.00 #K steel 43.00 W/m*KK water 0.58 W/m*Kflow water 300.00 GPHdensity of water 999.84 kg/m^3assumed D 1.64 inmass flow rate 0.32 kg/sviscostiy of water 3.15E-04 Pa*sCp water 4181.30 KJ/Kg-K

Relevant Parameters:

Heat transfer (conduction + convection)

Heating fluid in round channel

Reynolds number equation

Heat transfer coefficient

Results:Description Value UnitRe 16290.36 #prantle number water 7.00 #

nusselt number 117.30 #h forced convection 136.07 BTU/ft^2*hr*FQ 536.89 W 2147.55 W 7329.5956 BTU/Hrdelta t of water 10.00 oF

From these results we are able to find a heat exchanger that will be able to handle the required thermal load. The following components are suggested to make up the cooling system.

http://en.wikipedia.org/wiki/File:Thermal_Circuits.png

Thermal Analysis

Thermal analysis was performed to approximate the amount of heat generated from running the compressor. The heat of compression, heat from the inefficiencies in the motor, the heat from free convection, and radiation off the surface of the compressor were calculated. This document contains the calculations and results.

Heat of Compression ApproximationThe heat of compression was approximated so that a heat exchanger could be sized for the purpose of removing excess heat from the cylinder and compressed air. Assumptions and other necessary data are listed below.

Assume:Constant specific heat and specific heat ratioAtmospheric pressure in the cylinder at BDCFrictional losses are negligible

k 1.4Cp,air 1.004 kJ/kg-Kρair 1.29 kg/m^3Tamb 527.67 RPamb 14.7 psi

Table 1: Parameters

Bore 6 inStroke 5 inVclearance 3.3399057 in^3

0.0000547 m^3Disp. 141.37167 in^3

0.0023167 m^3Total Volume 273.90761 in^3

0.0044885 m^3Table 2: Cylinder Data

Temperature:

Pout(psi) Tout(F)51.25 293.9232349

Volumetric Flow Rate:

Mass Flow Rate:

Heat Generated:

51.25 psi

Speed(RPM) Flow Rate(cfm) Mdot (kg/min) Heat gen.(kJ/min) Heat gen.(BTU/hr)350 22.3369 1.9910 250.8944 14268.1225360 22.9751 2.0479 258.0629 14675.7831370 23.6133 2.1048 265.2313 15083.4438380 24.2515 2.1616 272.3997 15491.1044390 24.8897 2.2185 279.5681 15898.7650400 25.5279 2.2754 286.7365 16306.4257410 26.1661 2.3323 293.9049 16714.0863420 26.8043 2.3892 301.0733 17121.7470430 27.4425 2.4461 308.2417 17529.4076440 28.0807 2.5030 315.4102 17937.0682450 28.7188 2.5598 322.5786 18344.7289460 29.3570 2.6167 329.7470 18752.3895470 29.9952 2.6736 336.9154 19160.0502480 30.6334 2.7305 344.0838 19567.7108490 31.2716 2.7874 351.2522 19975.3715500 31.9098 2.8443 358.4206 20383.0321

Table 3: Calculated values for outlet pressure of 51.25 psi

Figure 1: P-V Diagram (Frame Side Cylinder)

Figure 2: P-V Diagram (Outer Side Cylinder)

P-V Diagram (Outer Side Cylinder)

0

10

20

30

40

50

60

-25 0 25 50 75 100 125 150

Volume(in^3)

Pres

sure

(psi

)P-V Diagram (Frame Side Cylinder)

0

10

20

30

40

50

60

-25 0 25 50 75 100 125 150

Volume(in^3)

Pres

sure

(psi

)

Room Temperature/ Ventilation Calculations

The ventilation of the room is important for the comfort of the people in it. The heat that is created by the compressor could potentially heat the room to unbearable temperatures if it is not dissipated. The amount of ventilation in the room must remove the heat from the compressor as well as the heat generated by the people operating the compressor and performing lab experiments. The heat emitted into the room was previously calculated from motor inefficiencies and black body analysis and was found to be approximately 3000 BTUs per hour. The table below shows all of the values that were needed to approximately calculate the air flow required to keep the test cell temperature at an acceptable level.

Description Symbol Value UnitsTemp of Machine Shop Tshop 70 Fo

Max Temp. Tmax 80 Fo

Heat From Compressor qcomp 3000 BTU/hrHeat Gen. From People* met 22 BTU/hr-ft2

Avg. Exposed Skin Area Askin 2 ft2

Number of People in Cell npeople 15 #Specific Enthalpy Exiting Air⁺ hin 26.2 BTU/lbSpecific Enthalpy Entering Air⁺ hout 29.8 BTU/lbSpecific Volume of Air (exiting) 1/ 13.71 ft3/lbRelative Humidity of the Shop RH 60 %*Metabolic heat generation for a person standing, relaxed⁺From psychrometric chart negligible moisture added from people

Heat generated from people was calculated from the following equation:

Rounding up to account for additional heat sources, the total heat generation is:

Conservation of energy for our control volume (test cell) is used in the following equations to calculate the necessary volumetric flow rate.

This calculation is a good approximation and depends on the number of people that are in the room operating the compressor, so the recommended ventilation flow rate should be 250-300 cubic feet per minute. The mechanical HVAC drawings of building nine indicate that the test cell (room 09-2329) should be equipped with two 12 inch diameter ducts that lead to exhaust fans on the roof (EF-31 and EF-32). Validation is required for duct functionality and if it will meet the new compressor’s needs.

1st floor drawing showing existing 12" ducts

Fan schedule: See EF-31 and EF-32

Acoustic Analysis

Part of the safety aspect of operating and maintenance of the compressor is ensuring that there will not be any acoustic damage or interference. The current planned site for the installation is the test cell located in the machine shop. The test cell is currently equipped with insulated door and wall.

It was assumed that with a full class, the doors will have to kept open for the class to view the compressor when it is operating. Worst case scenario, the doors will be open, a machine in the shop will be operating, and the compressor will also be operating.

Test- Used a sound level meter

o Mode: SPLo Range: A Hio Response: Fast

- Decibel value of the compressor when operating is approximately 85dB- Once compressor is installed, next team must verify that it operates at 85 db for

current calculations to be effective.

Table 1: Data from sound meter

Scenario 1, Class Time: Assuming door open, exposure to noises for an hour, machine in shop is running, and compressor is running

Dose < 50, hearing conservation is not needed when exposed for an hour

Scenario 2, Maintenance: Assuming door open, exposure to noises for 8 hours, machine in shop is running, and compressor is running

Dose > 50, hearing conservation is needed when exposed for 8 hoursMaximum length of time exposed to multiple noise sources with out hearing protection is 6 hours

Speech Interference LevelUsing the A-weighted dB measure compared the rating to the graph in Figure 1 to understand the furthest distance students can stand before background noises interfere with communication.

Figure 1: Permissible distance between a speaker and listener(http://www.nonoise.org/library/ane/pg47_ns5.gif)

With the compressor operating (85dB), the furthest the students can stand is 2ft away before it is difficult to hear the professor or lab guide. This will need to be taken into consideration when designing labs.

http://www.nonoise.org/library/ane/pg47_ns5.gif

ANSYS Models

Test CellThe test cell and surrounding rooms were modeled using SolidWorks. Dimensions

of the test cell and surrounding rooms were calculated using an AutoCAD file of building 9, provided by Facilities Management. This model was then imported into ANSYS to perform structural and modal analysis. The model was constrained at the top of the walls as well as basement walls. Using the built in ANSYS material list, the building was defined to be construction grade concrete. The weight of the compressor was then applied over the footprint of the skid on which it sits. The mesh was refined several to make sure the model was accurately capturing true deformation and stress values. After two iterations the deformation plateau at 0.00402in. ANSYS result as followed:

Figure 1: Deformation due to static load of compressor (top view) (MAX = .00402in)

Initial simulation for the testing of the static load of compressor revealed the floor itself was not structurally acceptable to support the compressor. With these larger then acceptable stress and deflection in the supporting surface our team worked with PE, Jason Vigil. It was recommended that two I-beams be inserted under the final location of the compressor as seen in figure 2.

Figure 2: Excerpt from PE report

I-beams were then modeled in Solid Works to the specifications laid out in the PE’s report. The I-beams were designed to the dimensions for a W8 x18 Beam as specified. The initial simulation had the beams located directly under the extremes of the skid. The material was defined as structural steel and imported into ANSYS. The I-beams were constrained as shown in figure 2 (at concrete beams and floor) and static loading simulations were recompiled.

Figure 3: Deformation due to static load of compressor with I-beams under skid extremes

With the addition of the two I-beams (figure 1) the deflection of the floor decreased to below 4 thousandths of an inch. Through communications with Jason Vigil, the results achieved in the ANSYS modeling aligned with values he had calculate and deemed safe. To determine if there could be any improvements by moving the I-beams more central, towards the highest deflection and stress areas, the ANSYS models were rerun with the beams moving inward in one-foot increments. As the I-beams were moved inward resulting in the max deformation traveling from .0037in to .0029in (figures 4, 5, 6) at three feet inboard of compressor skid. ANSYS results as follows:

Figure 4: Deformation due to static load of compressor, I-beams inboard 1 foot

Figure 5: Deformation due to static load of compressor, I-beams inboard 2 feet

Figure 6: Deformation due to static load of compressor, I-beams inboard 3 feet

In further discussions with Jason Vigil (PE), I brought up the results of the FEA. Through talking to him he stated that while the skid will be static, it makes sense to move the beams into the high stress areas. But when the compressor is operating there will be dynamic forces in play and the beams located at the extremes of the skid will be better able to cope and dissipate forces more uniformly.

Utilizing the same model, modal analysis was carried out to ensure that we did not encounter any resonance issues within the structure. The model was constrained exactly as from static analysis and simulations carried out. The frequency at which the compressor operates is 8.33Hz. The first mode was found at 58.59 Hz. The second mode was found at 64.69 Hz. And third mode was found at 76.30 Hz. These can be viewed in figures 7, 8, 9. ANSYS results as follows:

Figure 7: 1st mode vibrational response

Figure 8: 2nd mode vibrational response

Figure 9: 3rd mode vibrational response

In additional communications with our teams PE, Jason Vigil, he had arrived at natural frequency of 8.5 Hz, which was based on the floor structure alone, a rather conservative approach. With the addition of the walls to the model, a great deal of damping would be expected, but with a value of 58Hz results seems high. This could be due to a number of assumptions present in the model, such as empty rooms and perfect geometry. In conversations with the PE, he stressed his case stating that the models used are often grossly oversimplified to allow for the worst-case scenario. A more accurate natural frequency would be a located somewhere between the 8.5 and results achieved through modal analysis.

Compressor SkidUsing the documents provided by Dresser Rand, the skid was modeled in

SolidWorks and then imported into ANSYS. The skid was constructed from the material IS 2062. The skid’s I-beams are of the type ISBM 150. For purposes of analysis, the skid was constrained at each of its mounting locations, ten in total. The forces due to reciprocation were then applied to the model at compressor mounting locations. The mesh was refined several times in the areas of concern (front and rear mounting locations) to ensure the model was accurately capturing true deformation and stress values. After several iterations all values plateau ensuring accurate results. The moment due to reciprocation induced a maximum deformation of .0054in (figure 10) and a maximum stress of 7951.8psi (figure 11). ANSYS results as followed:

Figure 10: Total deformation of skid due to moment created by primary forces (MAX=.0054464 inch)

Figure 11: Stress due to forces generated from compressor.

Yield strength for material of skid (IS 2062) is 36,259psi providing a factor of safety present in the skid of 4.56. A factor of safety two-three is commonly used, but since this compressor is designed to operate in many different environments and have a fairly large lifespan, the increased FOS represents that need of safety in the wide range of operational environments.

Modal analysis was also carried out on the skid itself to see if the operational speed of the compressor would have and damaging vibration affects on the skid. The model of the skid was constrained identical to what was found in the static analysis. The 4th mode of vibration occurring at 182.21 Hz was found to be in the same direction as would be found from compressor operation (figure12). This mode is much higher than the operation speed of the compressor, resulting in no concern for any safety issues with resonance, though a slight pulse might be seen at this frequency from the accelerometer placed on the skid.

Figure 12: Modal deformation occurring at 4th mode, (182.21 Hz) significantly above frequency of compressor operation.

Installation Manual

Prior to the compressor being delivered to campus, the test cell should be fully prepped and ready to receive the compressor. The test cell should be cleared of any unnecessary storage, such as the Formula team’s old dynamometers, and fellow students’ design projects. Additionally the following should be carried out:

Prior to compressor arrival

Structural reinforcements

Following the plans set forth by our designs teams PE, Jason Vigil, I-beams should be installed as specified. Please review all documentation provided by Mr. Vigil in appendix 1. Quotes have been obtained for contractor cost and can be found in the budget. It is highly suggested to work with FMS to finalize the contractor.

Figure 1: Excerpt from Jason Vigil’s (PE) recommendations

Additional Electrical Requirements

Prior to the compressor arriving on campus the test cell should be outfitted with all the appropriate electrical supplies.

-220 volt 1 phase feed for the motor supply-120 volt supply for the data acquisition system-120 volt for ventilation and coolant pump requirements

A quote for the contracted work is located in the team budget. It is highly suggested to work with FMS to finalize the contractor.

Cooling Water requirements

Prior to the installation of the compressor in the test cell, the chilled water supply should be plumbed into the room for easy connection to the compressors cooling system. The compressors cooling system will be installed after the compressor is permanently located. See cooling system installation. It is highly suggested to work with FMS to finalize the contractor.

Ventilation Requirements

Contingent on whether the drawings in the ventilation calculations are validated, a single Greenheck GB-91 roof exhaust fan is more than ample. See ventilation calculations. Given that at 250 CFM, a 12 inch round duct will only generate a pressure drop of .015 inches of water per hundred feet. This is a very low pressure, at which the GB-91 could exhaust over 800 CFM. If the drawings are not confirmed and the GB-91 is not in place, then a similar, but smaller, exhaust fan could be used. 1/8 horsepower would be plenty to meet our needs. If the 6 inch duct must be used, then the horsepower should be increased to 1/6 to 1/4 horsepower due to the much greater pressure drop of 0.5 inches of water per hundred feet.It is highly suggested to work with FMS if a contractor is needed.

**For any questions pertaining to the additions to the test cell please contact Dave Harris or Dave Hathaway.

Scheduling Transportation

Boulter Rigging CompanyCoordination between RIT, Boulter Rigging Corp., and Dresser-Rand will be essential for smooth installation of compressor. Dresser-Rand will prepare the machine for shipment to Boulter Rigging Corp. in Webster, NY. The compressor will then be transported to RIT by Boulter and moved into the proper location. Proper equipment will be used to ensure safety and clearance constraints are met.

Boulter Rigging Company will be responsible for delivering the compressor to RIT as well as placing the compressor in its final resting place. The recommended delivery path shown in figure 2 shows the best path for delivery. It should also be noted that while the compressor is on the slab and not in its final resting place, the load must be distributed over a minimum of 60sqft as stated in Jason Vigils (PE) recommendations.

Figure 2: Installation path

- 45 feet of transportation across floor with basement underneath.- Loading bay area has foundation and can use fork lift until the entrance to the

old machine shop.- When being movied into location, the load must be distributed over 60 sqft

for adaquate load distribution.

Installation

MountingOnce the compressor is moved into the test cell it should be located as described in figure 3. The mounting holes should be marked and then compressor can be moved back out of the room to allow for the drilling of the mounting holes. Once the mounting holes are drilled and deemed adequate, the compressor can be moved back to its final location and the process of securing it can begin.

Figure 3: Top View of Test Cell with Components and Locations

After the compressor has been placed atop its mounting holes measures should be taken to ensure that the compressor is completely level. Using a level, shim the bolt holes until the compressor is level. After achieving a level compressor frame, the 12mm diameter grade 8 bolts can be pushed through to the bottom of the slab. On the bill of materials, it was suggested to purchase 108 inches of 12mm grade 8 threaded rods. If using the rods, it must be cut to 8 inch length prior to mounting. Using the appropriate washers, nuts and 6” x 6”x ¼” steel plates the sequence of tightening can begin (100 ft/lbs). Please also refer to figure 1 section 3 for plate installation. The bolts should also be tightened after the compressors first start up to ensure none have come loose.

Cooling System Installation

After the compressor has been installed, the cooling system can be outfitted to the machine. The location of the heat exchanger is not fixed. Locate a suitable location for the heat exchanger. Then the plumbing of the cold water supply to

the compressor can be carried out. Once the chilled water supplies are plumbed and secured, the placement of the coolant storage tank should be determined, remembering that a heating element will be placed within.

Figure 5: cooling loop diagram

The emersion heater probe should be installed into the storage tank. To do this, an approximate 2” hold should be drilled in the side of the tank. This hole is to allow for clearance between the plastic and the hot probe. Refer to the hazard analysis for possible dangers and mitigation. Next a stainless steel plate should be fabricated to allow for the attachment of the probe and for easy attachment to the storage tank. Once the probe has been installed to the tank, the tank can be secured within the room. Final plumbing of the cooling system can be carried out. Refer to figure 5 for cooling loop layout.

Sensor InstallThere are numerous sensors that will be installed onto the compressor. The scope of this project is to allow for flexibility in the location and configuration of all sensors. As laboratory experiments evolve, it may become necessary to add or move additional sensors to different locations. The following information includes sensor locations and manufacturers’ preferred installation methods for the sensors to be used in the DAQ system.

Sensor PlacementThe following locations are the preliminary mounting points for the sensors specified in Table 1.

Figure 6 - Top view Schematic of Dresser-Rand Compressor

Position Sensor Model # MountingA X-axis Velocity PCB VO622A11 Stud/Magnetic MountA X-axis Accelerometer PCB 623C00 Stud/Magnetic MountB Inner Bore Pressure PCB 102A21 Bore HoleC Z-axis Accelerometer PCB 623C00 Stud/Magnetic MountD Y-axis Velocity PCB VO622A11 Stud/Magnetic MountD Y-axis Accelerometer PCB 623C00 Stud/Magnetic Mount

Table 1 - Sensor Placements of Figure 1

B

C

D

A

Figure 7 - Air and Cooling Water Schematic

Position Sensor Model # MountingE Inlet Air Pressure PCB 101A05 Stud MountF Tank Air Pressure PCB 102A21 Bore HoleG Tank Air Temperature Omega RTD-NPT-

72-E-DUAL-MTPBore Hole

H Outlet Air Temperature Omega RTD-805 Adhesive MountH Air flow meter Omega FTB-936 Pipe FittingI Water Inlet Flow Rate Omega FV101 Pipe FittingI Water Inlet Temperature Omega FV101 Pipe FittingJ Outlet Water Temperature Omega FV101 Pipe FittingJ Outlet Water Flow Rate Omega FV101 Pipe FittingK Inlet Air Temperature Omega RTD-805 Adhesive Mount

Table 2 - Sensor Placement of Figure 2

E

F G

H

I

J

K

Figure 8 - Frame Oil Schematic

Position Sensor Model # MountingL Oil Temperature Omega PR-12 Pipe FittingL Oil Pressure PCB 101A05 Bore Hole

Table 3 - Sensor Placement of Figure 3

Adhesive MountAdhesive mounting bases are recommended to prevent an adhesive from damaging the sensor base or clogging the mounting threads. Below is a table of PCB’s suggested mounting adhesives.

L

Magnetic MountMagnetic mounts are to be used for temporary sensors on a magnetic surface. A thin layer of silicone grease should be applied between the sensor and magnetic base, as well as between the magnetic base and the structure.

Stud MountingThis type of installation is to be used for the permanent installation of sensors. First, grind or machine on the test object a smooth, flat area at least the size of the sensor base, according to the manufacturer's specifications. Then, prepare a tapped hole in accordance with the supplied installation drawing, ensuring that the hole is perpendicular to the mounting surface. Install accelerometers with the mounting stud and make certain that the stud does not bottom in either the

mounting surface or accelerometer base. A thread-locking compound may be applied to the threads of the mounting stud to guard against loosening.

Screw MountingLike a stud mount installation, screw mount installations are to be used on thin-walled surfaces. A cap screw passing through a hole of sufficient diameter is an acceptable means for securing the accelerometer to the structure. A thin layer of silicone grease at the mounting interface ensures high-frequency transmissibility.

Source: http://www.pcb.com/techsupport/tech_accel.php

DAQ InstallA key component to the educational application of this project will be with the use of the Data Acquisition system. The diagram below shows what will ultimatley be produced in the succeding projects.

http://www.pcb.com/techsupport/tech_accel.php

System-level overview of the compressor Data Acquisition System

At this point, all the sensors should be mounted on the compressor. It should also be noted that signal conditioners and connector cables for the sensors need to be specked out and purchased. At the time of this document’s publication, the total project budget, DAQ unit, and cable lengths are subject to change. These variables should be clearer once the compressor arrives on campus. Given the relationship with Dresser-Rand, it is possible that a NI PCI-4474 may be donated. For that reason, it is assumed that this will be the primary 8-channel DAQ for the LabView computer. Ray McKinney from Dresser-Rand in Olean, NY has been the primary contact for designing the data acquisition unit. From his contacts, he is currently investigating if he can get the temperature and pressure sensors donated for the project. He also might be able to get a PCI-4474 card either donated from National Instruments or from a customer recall site in Israel. Additionally, Ray has been working to get replacement sensors for the Omega products. We will be working with him in the future to see if these sensors can be swapped out for Bently Nevada Solutions.

High-level installation steps:1. Install as many sensors on the compressor as the budget allows.2. Install the NI PCI-4474 card (or final DAQ) onto the LabView Computer.3. Run and secure all cabling to sensors/signal conditioners to the LabView

Computer.4. On the LabView Computer, configure the LabView Compressor Project to accept

all the sensors. All the random number generators will have to be replaced, and all the sensors will need to be calibrated.

a. IP: 129.21.243.89 LOGIN: Dave PASSWORD: P094525. Test the DAQ to ensure it is measuring the correct information.

Bulleted Installation Procedure:- Formula Team has vacated room to new area to secure their stock materials:

o Temporary movement to another cell. Room should be vacated beginning the quarter prior to compressor arrival to allow for all contracted work to take place.

o Need to have clear access to floor and surrounding walls of Test Cell.o Engine Dyno will be removed from the back 4 feet of the room.

- Senior Design Team will prepare for the compressors arrival:o Order and purchase any items used in the installation process.

Boulter, storage racks, tools, sensors, etc. Mounting hardware and plates. Structural reinforcement by general contractor before compressor

is installed. Electrical services before the compressor is installed. Cooling pipe installation services by general contractor before

compressor is installed Orders should go out as soon as possible after approval.

o Provide necessary information to Boulter: On schedule and route for transportation. Materials necessary for install. Structural concerns and requirements.

Provide structural engineer’s analysis and suggestions.o Prepare the room for compressor:

Clean up and create a sustainable work environment. Ensure unrestricted access to all areas of the room and input

supplies. Mark and drill the required holes needed for mount installation

when compressor is placed in final position. Identify and mark the location of the control panel and emergency

stop. Room must be vacated of all materials to give sufficient room to

rigging company. Ensure that path to the room is clear of any obstructions.

o After Installation Assemble and install storage rack, desk, and work bench in test

cell Placement of these items should follow the Test Cell

Layout. Upon completion, these items will be used for storage of

equipment. Place computer, DAQ, tools, spare parts, etc. in proper locations Provide all safety material in the test cell.

Post signs and stickers Place necessary safety equipment in the room (see safety

document)

Install and hook up cooling system Coolant tank, heat exchanger, heater, valves and piping

Install and hook up sensors and data acquisition unit See sensor install for specifications and locations.

- Preparations by Boulter for relocation: o Transport machine from Dresser-Rand to Boulter Rigging Company

Provide sufficient time for Boulter to know machine. Verify that the correct equipment will be used and is available.

o Transport machine from Boulter Rigging Company to RIT machine shop loading bay.

o Upon arrival to RIT: Unload from truck with fork lift. Forklift will place machine on skates in new addition of shop.

o Use skates to transport machine across the machine shop Use no less than 4 carts to ensure sufficient load distribution Locate the carts underneath machine with proper access.

o Place machine in final location with mounts over bolt holes in floor. Place machine as precisely as possible with limited loads being

seen by floor.

Safety Manual

Prior to installing, operating, or performing maintenance on the compressor, review all safety procedures and operating manual. Be aware of all reciprocating components, electrical hazards, pinch-points, rotating parts, and pressurized equipment. Once the compressor is operational, there are normal daily operating procedures that should be maintained.

Observe All Hazard and Warning Labels

PERSONAL PROTECTITIVE EQUIPMENT

Always Wear the Appropriate Safety Gear

Safety glasses or goggles

Gloves

Ear protection

TORQUING SAFETY POINTS

These Are Unsafe Tool Uses! Never torque any fasteners or flanges on a unit that is running or pressurized

Use correct torquing procedures

Use correct size / range torque wrench

Do not use cheater bars or pipes on wrenches

Use thick wall sockets, no chrome sockets

Make sure you have good support to back up hydraulic wrenches and torque

multipliers

LIFTING SAFETYUse Your Legs, Spare Your Back

Know the weight of the item you are lifting

Bend at the knees (not your waist) and lift using your legs

Ask a co-worker to help with the load

Use a crane, hoist, fork truck etc. if in doubt

Proper Crane and Sling Use

Inspect all lifting straps and chains for

cuts or other damage before using

Verify lifting capacity of cranes or

chain falls

Check lifting eye bolts for bent or

damaged thread section

Use Proper Swivel Eye Bolts

LOCKOUT, TAG-OUT ELECTRICAL POWER

Before performing any work on the unit ensure

that the electrical power has been de-energized

and locked out at the breaker panel to prevent

accidental electrical shock or start up of the unit

Normal Daily Operating Procedures

• Check the oil level

• Check discharge pressure is zero

• Turn on the cooling water

• Start the compressor unloaded

• Select the compressor load: 50% or 100%

• Do this within 10 minutes to prevent overheating

• Compressor discharge pressure will rise to the setting of the backpressure valve (typically around 35 psi).

Normal Operation

Depressurize Before Valve Cover Removal

Be careful where you place your hands and finger when tightening the piston rod jam-nut with hammer wrench

Typical Reciprocating Compressor Cylinder Assembly

Cylinder Pinch-Points

Running Gear Pinch-Points

Pinch-Point Electric Motor Drive Belts Pressurized Valve Cover

Hot Discharge Temperatures: Compressor Cylinder & Discharge Bottle Electric Motor Shock Hazard

Hazards Analysis To ensure the safety of faculty and students during the use of the compressor, a

hazard analysis was performed. The team systematically went through the different sub components of the compressor and identified possible catastrophic failures.

The next team should review the hazard analysis, to ensure that there were not any areas overlooked. Each hazard should also be reassigned to the new team members to cover suggested mitigation or to create a new strategy.

Educational Labs

Investigation: Compressor P-V Diagrams & Efficiency

This investigation explores the concepts of isentropic compression in a Dresser-Rand single piston, double acting, reciprocating compressor. Utilizing a high sample rate pressure transducer located in the bore of the cylinder and a crank position sensor, we are able to generate real-time plots of pressure vs. volume. This can be compared with the theoretical pressure vs. volume diagram. Assuming adiabatic compression and negligible pressure drop through the valves, a theoretical p-v diagram can be generated. Do this by charting and plotting volume values for a variety of pressure values between atmosphere and the maximum absolute pressure that the compressor achieves (use the equation for adiabatic compression and expansion for values between atmospheric and the maximum pressure. Some important values are tabulated below and may be of use. The theoretical P-V diagram should look similar to the one shown below.

VTDC,Outer 2.545VTDC,Frame 0.795VBDC,Outer 143.916VBDC,Frame 142.167

P-V Diagram (Outer Side Cylinder)

0

10

20

30

40

50

60

-25 0 25 50 75 100 125 150

Volume(in^3)

Pres

sure

(psi

)

Assignment

Before starting the compressor, make yourself aware of all startup procedures and take all the necessary safety precautions. Before recording any data, be sure to run the compressor for a minimum of 5 minutes to ensure that the compressor has had time to reach steady state. Using the Labview interface, locate the thermal fluids lab 1 tab and begin logging pressure and volume data by pressing “Log Data” and saving the values in a .txt file format. The log data feature will automatically log data for a limited amount of time due to the large number of samples per second. These values can be imported into excel and plotted to create the experimental p-v diagram.

Create a formal report section comparing experimental data with theoretical predictions, following the guidelines and specific topics below.

Fully documented calculations for theoretical values. We will assume that the air entering the cylinder is at atmospheric pressure when the piston is at bottom dead center. Compute enough values to produce a nice smooth curve. When performing calculations, make sure that valve-opening pressure is identical to the experimental outlet pressure and the pressure in the cylinder is constant after the valve is opened. Be sure to incorporate the clearance volume in your calculations. State all assumptions.

Generate one chart with both theoretical and experimental plots. Discuss the general agreement between the measured pressure curve, and the

theoretical predictions. Do they agree within the experimental errors? If not, what else might account for the discrepancies (other than simple human error)? Compute average error in pressure over one cycle. Were our assumptions valid? Explain.

Using the information presented on the compressor interface calculate the efficiency of the compressor. What are some causes for the inefficiencies present in compressor?

Note:The Lab developed should be tested once the DAQ and compressor are operational to ensure they are suitable for student labs. This means having a Thermal Fluids lab professor as well as students test the lab and correct or modify any necessary aspects.

Investigation: Vibration of Compressor Skid

The single stage, dual acting compressor applies an oscillatory load on the skid that it is attached to. Refer to Figure 1 to see a diagram of this compressor. For this lab, use the accelerometer attached to the skid to acquire displacement data. With the data produce a spectral plot. After recording the frequencies shown by the spectral plot compare them to the ANSYS model developed by the Senior Design Team and your own model. Also record the maximum deflection.

Figure 1: Single Stage Dual Acting Compressor

ANSYS Modeling ResultsUsing the documents provided by Dresser Rand, the skid was modeled in

SolidWorks and then imported into ANSYS. The skid was constructed from the material IS 2062. The skid’s I-beams are of the type ISBM 150. For purposes of analysis, the skid was constrained at each of its mounting locations, ten in total. The forces due to reciprocation were then applied to the model at compressor mounting locations. The mesh was refined several times in the areas of concern (front and rear mounting locations) to ensure the model was accurately capturing true deformation and stress values. After several iterations all values plateau ensuring accurate results. The moment due to reciprocation induced a maximum deformation of .0054in (figure 2). ANSYS results as followed:

Figure 2: Total deformation of skid due to moment created by primary forces (MAX=.0054464 inch)

Modal analysis was also carried out on the skid itself to see if the operational speed of the compressor would have and damaging vibration affects on the skid. The model of the skid was constrained identical to what was found in the static analysis. The 4th mode of vibration occurring at 182.21 Hz was found to be in the same direction as would be found from compressor operation (figure 3).

Figure 3: Modal deformation occurring at 4 th mode, ( 182.21 Hz) significantly above frequency of compressor operation

Instructions1. Take deflection data from the accelerometers attached at the point where the body

of the compressor is bolted to the skid. These are the points where you will see maximum deflection due to vibratory load.

2. Generate a spectral plot wih LabVIEW3. Compare these results with you model as well as the ANSYS results show above. 4. Explain your results

Note:The Lab developed should be tested once the DAQ and compressor are operational to ensure they are suitable for student labs. This means having a Vibrations lab professor as well as students test the lab and correct or modify any necessary aspects.

Test Plans

Test Plan – Usability Testing

6-8 student test subjects, with 2nd to 3rd year engineering/computer abilities. 1-2 faculty test subjects. 5-10 minute overview of the project and compressor.

Tasks to be completed by each test subject:o Start up Compressor Interfaceo Turn program ono View Graphs Screen and see if they can easily interpret information on the

screeno Turn program offo Close out Compressor Interfaceo Access excel file

Assessment Factors:o Thought process of subject as they are performing actionso Frequency of help requestso Number of errors made in execution of instructions (ie Laboratory)o Time to complete task o Intuitiveness/Navigation/Aesthetics/comments

Other situations to test: Run program with the previous data file open while the new instance is set

to save to the same file name Run program with previous data file open while the new instance is set to

save to a different file name

Prior to First Run

E-Stop

1) Ensure power is connected to the control unit by using a voltmeter to check power

supply to the control unit.

2) Press the E-Stop button located in the front of the room.

3) Ensure that the control unit has lost power.

4) Reset the circuit breaker.

5) Press the E-Stop button located in the back of the room.

6) Ensure that the control unit has lost power.


8) Press the E-Stop button located outside of the room.

9) Check that the control unit has lost power.


Lock-Out Tag-Out for Control Panel

1) Pull down the power lever to shut down the main circuit breakers.

2) Use the lock-out tag-out lock to ensure the lock-out lever is restricted from moving.

3) Turn on the control panel.

4) Use a multi-meter to check that the control panel is not receiving power.

5) Turn off the control panel.

6) Un-lock the lock-out lever.

7) Pull the power lever up to return power to the main circuit breakers.

Measure and Adjust Machine Level

1) Check that the compressor is fully installed on the vibe-prevention mounts.

2) Place a level on the base of the compressor.

3) Check that the compressor is level. If it is leveled, no further adjustments are

necessary.

4) If it is not, determine the appropriate mount for adjustment.

5) Lift the compressor off of the adjustable mount.

6) Use a wrench to adjust the mount.

7) Return the compressor into the mount.

8) Check that the compressor is level. If it is leveled, no further adjustments are

necessary.

9) If it is not level, repeat steps 5-8.

Air Flow Results1) Obtain the test results for the air circulation from Dave Hathaway.

2) Ensure that the room air will be fully circulated at least every 15 minutes.

Miscellaneous Room Preparations1) Use a simple lamp, or any other safe electronic device, to test the room’s wall outlets.

2) Use a laptop and spare Ethernet cable to test the internet connectivity of the CAT-5

connection outlet located in the front of the room.

During First Run

E-Stops1) Start the compressor.

2) Press the E-Stop button located in the front of the room.

3) Ensure that the compressor has lost power.


5) Start the compressor.

6) Press the E-Stop button located on the control panel.

7) Ensure that the compressor has lost power.


9) Start the compressor

10) Press the E-Stop button located outside of the room.

11) Check that the compressor has lost power.


Visual Safety and Maintenance Checks1) Record all noticeable areas of moving parts that are potential safety hazards or pinch

points.

2) Record any unexpected noises that occur.

Lock-Out Tag-Out for Compressor1) Pull down the power lever to shut down the main circuit breakers.


3) Turn on the compressor.

4) Use a multi-meter to check that the compressor is not receiving power.

5) Turn off the compressor.



Room Sound Levels1) Obtain a Sound Level Meter from the Ergonomics Lab in the IE Department.

2) Record a sound measurement at a distance of 1m from the compressor.

3) Record a sound measurement at a distance of 1m from room 09-2329 with opened

doors.

4) Record a sound measurement at a distance of 10m from room 09-2329 with closed

doors.

5) Ensure all readings are within the safety requirements.

Room Temperature1) Obtain a type K thermocouple attachment and a multi-meter from John Wellin or a

Thermo-fluids lab.

2) Obtain a temperature reading from 10m outside of room 09-2329 as a baseline

ambient temperature value.

3) Stand in the center of the front half of room 09-2329, and record the ambient

temperature value every minute for 12 minutes (to provide 3 cycles of the air exhaust

system).

4) Stand in the center of the back half of room 09-2329, and record the ambient

temperature value every minute for 12 minutes (to provide 3 cycles of the air exhaust

system).

Vibrations1) Move outside the Test Cell (09-2329), shutting the door on way out.

2) Face the door to the Test Cell (one meter away from center) and make observations

on any vibrations felt.

3) If vibrations can be felt through floor (step 4), move back from Test Cell one meter at

a time until vibrations are no longer felt.

4) Repeat step 3 for all directions (right and left) and record values to create circle of

influence.

5) Make final observations about effects from vibrations of the compressor.

Removal and Re-install of Parts

Lock-Out Tag-Out for Compressor1) Pull down the power lever to shut down the main circuit breakers.


3) Turn on the compressor.

4) Use a multi-meter to check that the compressor is not receiving power.

5) Turn off the compressor.

6) Conduct any necessary part removals and re-installs.



Lifting Capabilities1) Bring the lift crane into the test cell room with the compressor.

2) Ensure that the lift crane can fully access the compressor.

3) Check that manual lifting is possible for any areas that are not accessible by the lift

crane.

Planning Documents

Finalized Bill of Materials

Current Budget and Expenditures

Scope of Supply

A scope of supply document was created based off the hazard analysis findings. With the ability to customize portions of the compressor, the scope of supply communicated RIT’s present specific needs to Dresser Rand.

- Relief Valve repositioned downward

- E-stop o Incorporate into control panel

- Bore Holeo Need two holes placed in the compression chamber (pressure transducer)o Need a hole placed in the discharge pulsation vessel (pressure sensor)o Need a hole placed in the oil sump (temperature sensor)

- Handles Welded on to access panels

- Clear strategically placed access panelso Purpose is to view components in motiono Suggested material – Lexan

- Replace 480V 3 phase motor with 220V 1 phase motor

Finalized QFDThe quality function deployment assisted in the planning of engineering metrics, identifying customer needs, and tracking progress during the design phase.

Appendix

Cooling Loop Calculations &...

Documents

Transcript of Cooling Loop Calculations &...