Reciprocating Compressor Installation and...

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Reciprocating Compressor Installation and Validation MSD II - 11452 John Blamer (ME) – Team Leader Promit Bagchi (ME) – Lead Engineer Elliot Kendall (ME) – Hydronics Engineer Matthias Purvis (ME) – Operations Engineer

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Reciprocating Compressor Installation and Validation

MSD II - 11452

• John Blamer (ME) – Team Leader • Promit Bagchi (ME) – Lead Engineer • Elliot Kendall (ME) – Hydronics Engineer • Matthias Purvis (ME) – Operations Engineer

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• Background

• Project scope

• Deliverables

• Installation – Current State of Design

• Delivery

• Mounting

• Coolant System

• Compressor Sheave/Internal Components

• DAQ

• Conclusion

• Recommended Future Tasks

• Permanent DAQ Solution

• Thermodynamics Lab

• Vibrations Lab

• Questions

» Agenda

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» Background

• Continuation of SD group P09452

• Reciprocating compressor donated to RIT by Dresser-Rand

• Installed in ME Machine Shop

• For research and educational purposes

• P09452 did significant preparation work

• Shipped from D-R facility in India

• Should have arrived in Port of New York on October 25th

• Trucked to Boulter Rigging

• Delivered and installed at RIT December, 17th

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» Project Scope

• Understand compressor

• Basic operation

• Hardware

• Understand installation needs

• Vibration isolation

• Cooling system

• Electrical and DAQ

• After install, focus on education and

Beginning of Life characterization

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» Deliverables

• Compressor installed and operational by end of 2010-1

• Implement a preliminary DAQ system

• Measure/document beginning of life data from the compressor

• Review, test, and validate the Thermodynamics and Vibration labs created by

P09452

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» Installation – Installation Issues

• Original compressor location would interfere with large concrete beam

• 12”x14” concrete beam directly under bolting locations

• Moved unit 12” in Y-direction to avoid beams

• X location maintained to remain within support of I-Beams

• Two bolt holes would interfere with I-Beam

• Concrete anchors to be used in those locations

• Better position

• Control panel door clearance

• Ample space around unit

Y

Concrete Beam

I-Beams

View from Basement

Concrete Beam Original Location

X

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» Installation – Delivery Issues

1.) Compressor would not fit through test cell door frame

2.) Compressor is 3” wider than expected (control panel)

3.) Possible Solutions:

Bring compressor in at an angle

Remove door frame

Cut-off control panel and relocate 4” in-board towards compressor

4.) Selected:

Cut-off control panel and relocate 4” back towards compressor

5.) Confirm idea with Dresser-Rand

Instruct Boulter on modification on the morning of delivery

6.) Successfully fit compressor into test cell

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» Installation - Mounting

• Unit can create significant vibrations

• Vibrations must not be transmitted to building

• 10 vibration-isolating mounts donated by LORD

Corp.

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» Installation - Mounting

• Adapter plates fabricated to attach mounts to frame

• Mounting holes drilled in compressor frame

• Mounts bolted through concrete floor

• Hammer drilling caused damage to floor

• 7 bolts through floor, concrete anchors for remainder

• Repaired with SpeedCrete PM Concrete Repair

• 6”x6” steel plates under floor

• Plans approved by Jason Vigil – Jensen Engineering

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» Installation – Coolant System

• Supply cooling water to compressor

• 4-6 gal/min

• 80°F water to prevent condensation

• 30-60 psi pressure

• Thermostatic mixing valve

• Water reservoir

• Water pump

• Heat exchanger

Section

Pressure

Drop (psi) Head loss (ft)

1 -- 2 (Piping) 0.058 0.134

2 -- 3 (Compressor) 14.000 32.516

3 -- 4 (Piping) 0.058 0.134

4 -- 5 (HX) 8.000 18.580

5 -- 6 (Piping) 0.058 0.134

6 -- 7 (Tank) 0.044 0.102

7 -- 8 (Piping) 0.057 0.134

8 -- 1 (Pump) -27.843 -64.669

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» Installation – Original Cooling System

• Original system donated by Professor John Wellin

• 50 gal reservoir

• 1/3 hp pump (Insufficient flow)

• Heater w/ circulating pump

• Flow-meter

• Upgraded motor turned out to be insufficient

• Pulling excessive amperage

• Overheating

Original System

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» Installation – Coolant System

• Replaced pump with Multi-Stage Dayton Pump

•1/3 hp, 8-stage

• Modified frame to accommodate new pump

• Pump operating in optimal range

• Added pressure gauge

0

50

100

150

200

250

300

0 5 10

He

ad (

fee

t)

Flow (gpm)

Dayton 1/3 HP Multi-Stage Booster Pump Curve

Final System

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» Installation – Compressor Sheave/Internal Components

• Attach ~150lb compressor sheave (pulley)

• Position balance weight in correct location

• Alignment of compressor and motor sheaves

• Attach Belts

• Tighten belts to specified load

• Install scraper rings

• Install packing rings

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» DAQ

X-Axis Accelerometer

Y-Axis Accelerometer

Signal Conditioner

National Instruments

USB DAQ System

Laptop

Signal Conditioner

Signal Conditioner

Z-Axis Accelerometer

Flow chart of current DAQ system

• Stud mounted accelerometers (X,Y, Z)

• Signal conditioners

• USB DAQ device with 8 analog inputs

Signal Conditioners

Accelerometers USB DAQ Enclosure

Z

X

Y

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» DAQ

-4

-2

0

2

4

6

0 0.1 0.2 0.3 0.4 0.5

Acc

ele

rati

on

[m

/s2]

Time [sec]

Compressor Oscillatory Response

X

Z

Y

X Y Z

Amplitude (m/s2) 3.629 0.900 1.480

Frequency (Hz) 6.448 12.879 6.434

• Primary vibration occurs at 6hz (360rpm)

• Correlates to piston motion

• Smaller vibration signature at 12hz

Amplitude vs. Time

Amplitude vs. Frequency

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» Conclusions

• Completed:

• Installed compressor and prepared it for testing

• Vibration isolation, and cooling system

• DAQ system, accelerometers, and characterized vibrations data

• Incomplete:

• Acquire all of the recommended sensors

• Completely characterize compressor performance

• Test and revise thermodynamics and vibrations labs

• Could have accomplished more by:

• Utilizing better risk management

• Purchasing all necessary components earlier

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» Recommended Future Tasks – Permanent DAQ Solution

• Fully understand pros and cons of current USB DAQ system

• Invite personnel from National Instruments to come to RIT

• For advice on which system would be best for research and educational

needs.

• Work closely with Dresser-Rand to see what DAQ systems they use

• Dr. Kolodziej would like a similar set-up as DR

• Needs to fit within our allotted budget

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» Recommended Future Tasks– Thermodynamics Lab

• Review and revise Thermodynamics Lab previously created by P09452

• Test lab with current Thermodynamics students and/or professors

• Lab needs to be error free, easy to follow and achievable

• Acquire necessary sensors

• Recommendations:

• 2 pressure sensors to be placed in the existing fittings located on the piston cylinder

• (See picture)

• Encoder to measure crankshaft rotational speed

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» Recommended Future Tasks – Vibrations Lab

• Create new Vibrations Lab

• Possibly including:

• Comparison of theoretical and actual vibration transmissibility

• Using LabView, make a Acceleration vs. Time graph

• Graph Frequency Response

• Install shock absorber, measure change in deflection

• Thoroughly test lab

• Needs to be error free, easy to follow and achievable.

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» Recommended Future Tasks – Hardware

• Construct new cooling system frame

• Steel construction rather than wood

• Smaller reservoir

• More compact design

• Implement a damping system to reduce compressor oscillation

• Utilize adjacent room for Control Room

• Correct power-on switch on control panel

• Collect vibration data in various locations on the compressor frame

• Incorporate filter or bypass valve for sediment in cooling system

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» Lessons Learned

• Always double check critical calculations

• No detail is too insignificant to overlook

• Seek professional guidance in unfamiliar situations

• Always verify the accuracy of background information and existing

project documentation

• Expect delivery delays

• Don’t expect systems to interface immediately

• Cost should be a secondary concern to functionality

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• Special thanks to:

• Dr. Kolodziej

• Bill Nowak

• Scott Delmotte

• Dresser-Rand Corp.

• LORD Corp.

• Dave Hathaway and ME Machine Shop Staff

• John Wellin