Sneha Rao – Project Manager Edward Budriss – ME Alex Scarangella – ME Edward Wolf – CE Anna Cheung – ISE P09452

Background This is the second iteration of the project (P09452) Previous compressor (P08452) had an ITAR designation that made it unsuitable for RIT needs Dresser-Rand is donating a single stage, double acting, horizontal, reciprocating compressor Primary customer of the project Dresser – Rand: test future health monitoring RIT: research and facilitate lab

Objective of P09452 Prepare installation document Create a system to monitor activity, facilitate labs, and prepare for future health monitoring Develop lab procedures Ensure the compressor is safe for lab use by students and faculty

Installation – Structural Integrity Created simulations in ANSYS to perform structural and modal analysis to target areas of concern Modal analysis showed that structure would not be affected In the test cell,.00402” deformation due to static load Initial simulation showed that floor was not structurally acceptable

Installation – Structural Integrity Worked with PE to determine reinforcements Chose two steel I-beams placed at the extremes of the skid to dissipate forces Compressor skid was also modeled to determine deflection and factor of safety Yield strength for material of skid provided a factor of safety of 4.56

Installation - Ventilation Based on heat coming off compressor and amount of people in the room, calculated the air flow necessary Heat emitted into the room was previously calculated by motor inefficiencies, and black body analysis, approx. 3000BTUs/hour DescriptionSymbolValueUnits Temp of Machine ShopT shop 70FoFo Max Temp.T max 80FoFo Heat From Compressorq comp 3000BTU/hr Heat Gen. From People*met22 BTU/hr- ft 2 Avg. Exposed Skin AreaA skin 2ft 2 Number of People in Celln people 15# Specific Enthalpy Exiting Airh in 26.2BTU/lb Specific Enthalpy Entering Air ⁺ h out 29.8BTU/lb Specific Volume of Air (exiting) 1/  13.71ft 3 /lb Relative Humidity of the ShopRH60% *Metabolic heat generation for a person standing, relaxed ⁺ From psychrometric chart negligible moisture added from people

Installation - Ventilation Upon confirmation of drawings for present ventilation capabilities: Current ventilation system that contains GB-91 exhaust fan, 12” diameter ducts, EF-31, and EF – 32 exhaust fans on the roof would be adequate if all equipment is available Research an exhaust fan that is similar with 1/8 horsepower

Installation – Transportation/Mounting Work with Boulter Rigging Dresser-Rand → Boulter Rigging → RIT 45’ of transportation through Building 09 Load must be distributed over 60ft 2 using skates Mount using shim, 12 mm grade 8 bolts, nuts, and steel plates

Installation – Cooling Loop Chilled water supply must be plumbed into the test cell Cooling system must remove 40,000BTU/hr Inlet coolant temperature needs to be maintained at 10°F above ambient air temperature System includes: Pump: 300 GPH, 115V, ½” Heat exchanger: ¾ NPT inch connection, 8x3.25x 2.25” Coolant tank: Poly storage tank 22x10x8” Immersion heater: 400W, ⅝” diameter, ½ NPT Flow meters

Installation – Cooling Loop

Installation - Acoustics To ensure safety of operators in the test cell, performed acoustic analysis to determine the noise dosage Assuming a typical lab situation, exposure of an hour would not require ear protection Assuming extended maintenance, exposure of 8 hours would require ear protection Lab Situation Extended Maintenance

Installation – Interface Chose sensors that will facilitate educational labs and prepare the compressor for future health monitoring Specified ideal positions and mounts to assure versatility Researched DAQs that will integrate smoothly with the selected sensors

Installation – Sensors PositionSensorModel #Mounting AX-axis VelocityPCB VO622A11Stud/Magnetic Mount AX-axis AccelerometerPCB 623C00Stud/Magnetic Mount BInner Bore PressurePCB 102A21Bore Hole CZ-axis AccelerometerPCB 623C00Stud/Magnetic Mount DY-axis VelocityPCB VO622A11Stud/Magnetic Mount DY-axis AccelerometerPCB 623C00Stud/Magnetic Mount

Installation – Sensors PositionSensorModel #Mounting EInlet Air PressurePCB 101A05Stud Mount FTank Air PressurePCB 102A21Bore Hole GTank Air TemperatureOmegaRTD-NPT- 72-E-DUAL- MTP Bore Hole HOutlet Air TemperatureOmega RTD-805Adhesive Mount HOutput Air PressurePCB 102A21Adhesive Mount HAir flow meterOmega FTB-936Pipe Fitting IWater Inlet Flow RateOmega FV101Pipe Fitting IWater Inlet TemperatureOmega FV101Pipe Fitting JOutlet Water TemperatureOmega FV101Pipe Fitting JOutlet Water Flow RateOmega FV101Pipe Fitting KInlet Air TemperatureOmega RTD-805Adhesive Mount

Education – Thermal Fluids Explores the concepts of isentropic compression 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 Compare real-time plots with the theoretical pressure vs. volume diagram

Education – Thermal Fluids Assuming adiabatic compression and negligible pressure drop through the valves, a theoretical p-v diagram can be generated Chart and plot 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) V TDC,Outer V TDC,Frame V BDC,Outer V BDC,Frame

Education - Vibrations Create a theoretical model using vibration analysis Calculate the maximum deflection on the compressor Then using the data logged from the accelerometer attached to the skid, measure the deflection on the skid. Compare the theoretical and experimental data. Include the ANSYS analysis.

Test Plans Usability Tests E-Stop Prior to first run and During first run Lock-out Tag-out Prior to first run, During first run, Removal and Reinstall of parts Air Flow Sound Levels Room Temperature Vibrations Lifting Capabilities

Requests from Dresser-Rand Created scope of supply based on hazard analysis and specific needs Requests: Reposition relief valve downward Incorporate E-Stops into control panel Five holes drilled into compressor Handles welded on to access panels Clear lexan access panels Replace 480V 3 phase motor with 220V 1 phase motor

Supplying to Future Team Calculations and Simulations Cooling Loop, Thermal Analysis, Ventilation, Acoustic, ANSYS Installation Manual Includes necessary contracted work, mounting of compressor, hardware needed, ventilation requirements, cooling loop, sensors, location for sensors, and DAQ Safety Document Educational Labs Test Plans Planning Documents