RIT SENIOR DESIGN: P08452 COMPRESSOR INSTALLATION, REVAMP, AND INTERFACE

Warning Signs for Test Cell

Warning Stickers

Warning Sign Locations Large signs to be located visibly on test cell wall near power/control panel Small labels will be placed on the compressor near hazardous components Components include – Drive belts – Cross head – Electric panels – Cylinder outlet piping – Cylinder heads

Revamp Guide

Air Side Parts Removed Figure Index NumberDescription 5Fifth Stage Cooler 9Fourth Stage Discharge Piping 11Fourth Stage Cooler 14Sixth Stage Relief Valve 21Sixth Stage Cooler To Separator Piping 23Sixth Stage Cooler 24Sixth Stage Separator 26Final Discharge Piping 27Tailpiece 28Tailpiece 29Adapter 30Back Pressure Valve 31Final Discharge Check Valve 36Third Stage Relief Valve 38Fourth Stage Inlet Piping 39Third Stage Separator 45Third Stage Cooler 56Third Stage Discharge Piping 61Third Stage Interstage Piping 62Sixth Stage Inlet Piping 63Sixth Stage Discharge Piping 64Pulsation Bottle 65Tee 66Tailpiece 67Inches of Pipe (2) 68Fifth Stage Relief Valve 69Fourth Stage Relief Valve 70Tailpiece 72Seal 73Tee 74Tailpiece 75Fourth Stage Separator 76Fifth Stage Separator 77Fifth Discharge Piping 78Sixth Stage Bottle to Cooler Piping 79Fifth Stage Inlet Piping Location of new air output 6 th Cooler 3 rd Cooler 6 th Separator 4 th Cooler 4 th Separator 5 th Separator 3 rd Separator 5 th Cooler Pulsation Bottle

Figure Index NumberDescription 34Fifth Stage Cooler Piping 38Fourth Stage Cooler Outlet Piping 47Sixth Stage Cooler Outlet Piping 48Third Stage Cooler Outlet Piping 49Third Stage Cooler Inlet Piping 54Fourth & Sixth Stage Cooler Inlet Piping 55Fifth Stage Cooler Inlet Piping Open Loop Cooling Parts Removed Plug manifold where piping removed

Freshwater coolant needs to be rerouted from 2 nd stage exit on block to freshwater inlet on heat exchanger. Closed Loop Cooling Modification

Cylinder Removal 4 th, 5 th, & 6 th Cylinder heads being removed The 2nd stage uses only the downwards stroke for compressing the air. Therefore the 5th and 4th stage cylinder assemblies can be removed. A block off plate would be bolted in place of them. Problem The 6 th stage piston acts to seal the upper 1 st stage compression chamber (next slide.) 6 th 4 th 1 st 2 nd 3 rd 5 th Pistons 1 st double acting 2 nd, 3 rd single acting downward stroke 4 th, 5 th, & 6 th single acting upward stroke Revamp Compression volume Compression volume not utilized

6 th Stage Block Off Plate Assembly The original upper 1 st stage seal was achieved with o-rings on the 6 th stage cylinder that is into the 1 st stage head. Existing 6 th Stage Cylinder and Piston 1 st Stage Outer Cylinder Head + = 1 st Stage Head with 6 th Stage Cylinder Installed The new design uses a fake 6 th stage cylinder to fill in the area used by the original. O-ring grooves are cut on the fake 6 th stage.

Counterweight Location To Pistons Possible locations: On the side of the piston not used for compression (bottom of 2 nd and 3 rd stages only.) – 1 st stage compresses on both sides of piston therefore complicated. Would require much more parts. Replace oil flingers with weights. – Would also perform the same job as flingers. Attach weight to crosshead. – DR tells us this has been a proven method in the past. Bingo…

Counterweight Design Area above crosshead was chosen for counterweights: Availability of space. Existing threaded holes. Simple design. Dresser-Rand success with this location in the past.

Condensate Drain Modification

Operation and Maintenance (O&M) Manual Single-point initial resource for future teams Contact Information: – Student Team P08452 – RIT Faculty and Staff – D-R Main Contacts and Representatives – Others provided where applicable throughout Technical Information: – Safety Considerations – Procedures – DAQ Interface – Engineering Details – Appendices

O&M Manual Table of Contents

O&M Manual Safety Considerations Dresser-Rand Manuals Referenced General Safety Equipment Specified Operational Safety Procedures Safety Signs and Labels Summary of March 28, 2008 Compressor Safety Practices Training

O&M Manual Procedures Installation Requirements – Formula Team – Senior Design Team – RIT (Structural Capabilities Required) – Boulter Rigging Company – Vibration Dampening Mounts Test Plans Startup & Shutdown Procedures

O&M Manual DAQ Interface Tutorial – Step by step guide – Descriptive pictures Usability Testing Data Collection – Objective and subjective data forms – Results of Usability Testing

O&M Manual Engineering Details Simple descriptions of major design changes – N30 Compressor – Test Cell Room References to locations of further details are provided where appropriate

O&M Manual Appendices Appendix A: – Compressor Safety Practices, Dresser-Rand Appendix B: – Structural Analysis, Jensen Engineering, P.C. Appendix C: – Revamp Guide, Senior Design Team P08452

Interface Results Specifications Need #MetricUnitsMarginalIdeal Need met? 1Measure ParametersList-- Yes 2Trend DataBinaryYes 3User FriendlyList-- Yes 4Notify of FailureBinaryYes 5Store DataBinaryYes 6Remote AccessBinaryYes Yes* 7Easily ModifiedList-- Yes *Remote access can be accomplished via Windows Remote Desktop, so no additional work was performed on this metric. Additional Accomplishments A donated computer was upgraded for future teams to utilize

Usability Testing Tests were performed on users with varying degrees of computer skill to see how fast they could learn to complete basic tasks on the interface. Each user was given two tries to perform a set of five tasks, and errors as well as help requests were recorded. Time to complete each task was also recorded to see if the users could improve in as little as 2 rounds.

Usability Results TaskRound 1 (s)Round 2 (s)Total errorsTotal help requests Start up LabVIEW2200 Turn interface on View Graph of stage Turn interface and LabVIEW off Check crank angle after 20 iterations via the data file Conclusion:Users showed drastic improvement from rounds 1 to 2. Errors and requests were minimal in both rounds. Since the users ranged from novice to expert in computer experience, the results show that the interface allows someone with any computer background to perform operations. Extra notes:  All testers chose to use only the tabs to switch screens rather than use the buttons.  Two of the three testers chose to stop the program via the LabVIEW abort button rather than the stop button which is part of the interface.  Two thirds of the users stated the interface was exceptional, one third said it was average

Future Team Goals Data currently recorded ( and their thresholds ) would need to be changed for a different compressor Sample rate calculator would need to be modified to accept the DAQ sample rate (currently uses random data) Program would need to be modified to accept data from the DAQ A suitable DAQ for a new compressor would need to be found (FieldPoint, CompactRIO, CompactDAQ) as well as sensors

Interface Screenshots

Structural Analysis Floor originally designed for 80 lb/ft2 live load. – Compressor exceeds live load (372 lb/ft2) – Strengthen by placing 2 W8X18 Steel Beams under the compressor – Remaining structure is adequate to support compressor Dynamic analysis of the floor structure – No necessary changes. – Frequency of the floor is about 8.5 Hz Greater than operating frequency of compressor – No specific deflection requirements are required. Transporting the compressor – Redistribution of load over an area of at least 60 ft 2. Location of rebar in concrete floor should be determined. – Hire a construction testing company for locating existing rebar. Analysis can be used as benchmark – Structural support should be added for future projects and equipment. – Specified mounts should also be used with the installation of equipment with dynamic loads.

Recommendation to Strengthen Floor

Contributions to Next Project N30NL Compressor will not be donated – ITAR designation of the machine Projects will continue – New compressor will be donated – Recreate the scope based on future compressor – Same intended future projects Many details can be used as a guide – Safety, Installation, Revamp, Interface, O&M Manual

Contributions: Safety Equipment is Available – Earplugs, Safety Glasses, and Gloves Safety Warning Signs to be placed in room Room Capabilities Verified – Mitigation of noise levels – Structural Capacity Procedures have been outlined Contacts for Safety Training – Presentation is available on computer

Contributions: Installation Boulter Rigging Company for installation Structural analysis as benchmark Room layout has been created – Adjust for future compressor – Storage Shelving and Workbench Tools for maintenance have been provided – Metric and SAE applications Vibration Mounts – Attempting to return to supplier – Identified for use on future project Adjust quantity and positioning as needed Room has been cleaned and prepared – Paint and supplies are available to finish other half of room – Floor will be stripped and cleaned over the summer.

Contributions: Revamp Theory and equations – Compute resulting changes from revamp – Mechanical Power, Electrical, Cooling, Vibrations Concepts – Stepping down a reciprocating compressor – Counterweights – Flow path changes – Removal parts Guideline for proper documentation – Revamp Guide Test plans for specifications

Contributions: Interface Upgraded computer with LABVIEW Working GUI interface – User guide – Collects data – Easy to update for future compressor needs Identifies trouble spots in data Specifications on hardware – DAQ and collection equipment – Suggested bill of materials and budget

Higher Level Documentation Poster – Shown at “Imagine at RIT” – Final copy for Dresser-Rand and RIT – Highlights of capstone design process Technical Paper (ITAR Friendly) – Published in RIT Publication – Canadian Machinery Vibrations Association Submit in July for publication Conference in October

High Level Customer Needs and Engineering Specs Safety Considerations – Equipment List – Trainings – 70-95°F Maintenance Capabilities – 24”-35” Access Space – ft 2 Storage Space – Tooling List – < 40 lbs. Manual Lifting – lbs. Assisted Lifting Installation of Compressor – Guidelines and Contact Information – 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

Bill of Materials and Expenditures

Overall Projects Timeline

Acknowledgements Dresser-Rand Scott Delmotte Joe Tecza Ray McKinney Bob Smith Andy Blide Dave Decker Mike Bunce Allan Kidd RIT Dr. Margaret Bailey Dr. Mark Kempski Dave Hathaway Rob Kraynik Steve Koscial Ryan Crittenden Dr. Edward Hensel Greg Evershed