Reciprocating Compressor Installation and...
Transcript of Reciprocating Compressor Installation and...
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
• 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
» 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
» 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
» 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
» 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
» 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
» Installation - Mounting
• Unit can create significant vibrations
• Vibrations must not be transmitted to building
• 10 vibration-isolating mounts donated by LORD
Corp.
» 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
» 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
» 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
» 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
» 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
» 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
» 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
» 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
» 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
» 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
» 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.
» 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
» 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
• Special thanks to:
• Dr. Kolodziej
• Bill Nowak
• Scott Delmotte
• Dresser-Rand Corp.
• LORD Corp.
• Dave Hathaway and ME Machine Shop Staff
• John Wellin