P08452: Reciprocating Compressor Install, Revamp, and Interface Dr. Margaret BaileyFaculty Guide Garry StudleyProject Manager Dave Rigolo Lead Engineer Alec JarvieIndustrial Systems Engineer Chris NeitzComputer Engineer Kiernan French Mechanical Engineer

Original N30NL-4 Description 6 Stage Vertical Reciprocating Air Compressor –30 CFH at 3000 PSIG –Positive Displacement Designed for Automated Operation Used on Naval Ships –Destroyers and Carriers Original Cost/Actual Value –$400,000/$800,000

Project Description Installation at RIT – Engine Test Cell Redesign of Machine –6 Stages -> 2 Stages –3000 PSIG -> ~100 PSIG –75 HP -> ~25 HP –Consider future uses Interface Setup –Future data acquisition

High Level Customer Needs and Engineering Specs Safety Considerations –Equipment List –Trainings –70-95°F Maintenance Capabilities –24”-35” Access Space –30-45 ft 2 Storage Space –Tooling List –< 40 lbs. Manual Lifting – lbs. Assisted Lifting Installation of Compressor –8-19 Weeks from 12/3/07 –Acoustic Levels dB –Vibrations g/s –0 injuries –Room Structural Load =15,000 lbs (n f = 2.0) Compressor Revamp –6 to 2 Stages – hp –100+/-10 psi – A Future Use Considerations –Modifiable Interface –Modifiable DAQ Variables –Timeline for Projects –Allowances for Projects Dresser-Rand Involvement –Weekly Teleconference Meetings –Bi-weekly Reviews –Operation and Maintenance: Student Manual

Safely convert compressor from 6 to 2 stages Safely install compressor Create a functional interface to log and trend data – Installation and interface relate via the installation of a suitable computer workstation 2 – Interface and revamp relate through the documents both sub functions will produce for future teams to use 3 – Revamp and installation are related through the creation of a safe environment suitable for the revamp of the compressor 4 – All sub-functions work together to provide a safe, solid, and functional foundation for future teams to pursue further revamp and fault detection projects Relationships of Sub-functions

Development Process

Safety Considerations Vibration shutoff switch –due to excessive vibrations Emergency kill switch –2 e-stops to ensure safe exit from room Lock-out Tag-out Panel –Prevent electrocution and pinch hazards Safety equipment –Eye, Ear, Hand and Foot Protection Fire Hazards –2 fire extinguishers for ABCD type fires Signage –Warnings, Hazards, and Exits Clearly marked Vibration-Monitoring Switch

Concept Description: Installation Test Cell Layout Installation procedure and preparations Boulter Rigging Corporation: Used to transport and place machine Necessary Supplies: Storage Rack, Workbench, Desk, Tools, Tool Chest Top View of Test Cell with Components and Locations Section A-A: Basement view of Test Cell and Compressor Position

12X Primary design intent: Reduce amount of vibrations transferred to floor and surrounding building Maintain machine position Distribute weight on floor 12 Heavy duty spring mounts are to mounted along he perimeter of the machine using existing mounting holes. Concrete anchors will attach the mounts to the floor. Spring Mount Specifications Highest vibration isolation from floor (Need 5.4 Reduce Vibs Impact) High deflection if needed to absorb serve vibrations (Need 3.4 Scale Down Vibs) Distributes weight to 12 21in^2 areas on floor (Need 1.2 Safety, Structural) High weight capacity (13200lbs) (Need 1.2 Safety, Structural) Anchoring to floor (Need 1.1 Safety, Install) Reasonable Price and Labor Concept Description: Mounting

Concept Description: Revamp Power –Reduced to 25 HP (Calculated) Electrical –37.5 Amps (Calculated) Cooling –17°F  T in Open Loop Cooling (Fresh Water) –Exhaust Considerations

Concept Description: Interface System to acquire and trend data from the compressor –Temperature –Pressure –Flow –Crank angle –Vibration –Valve timing LabView chosen as program to interconnect interface and DAQ DAQ device will be purchased from National Instruments

Concept Design of Interface Initial design Measurements organized by stage and type Includes options to change sampling time, save files

High Risk Assessment Mitigated –Sound (D-R Data, Dissipation Experiment) –Vibration (Spring-Action Damping Mounts) –Budget (Coordination between D-R and RIT) Remaining –Structural Load (Consultant Lead Time) –Formula SAE Team (Exit Test Cell )

Current State of Design Designs meet all customer needs Designs meet engineering specifications except for: –Structural load capabilities not confirmed On target to meet project budget pending: –Costs for Electrician and Structural Consultant Schedule: –Only possible issue is compressor arrival due to consultant lead time Mitigations: –Environmental effects from machine (Heating and Sound) –Lifting and access specifications for motor removal

Student Version Operation and Maintenance Manual Auxiliary Document, attached to the N30NL-4 “Maintenance Manual” Starting Guide for Future Project Teams Safety Considerations Procedures Engineering Details

Overall Projects Timeline

Installation, Revamp Designs, and Interface Developments Installation and Interface Design Timeline

Senior Design II Timeline