1. 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

2. Original N30NL-4 Description 6 Stage Vertical Reciprocating Air Compressor –30 CFH at 3000 PSIG –Positive Displacement Designed for Automated Operation/Oil Free Used on Naval Ships –Destroyers and Carriers –Turbine/Diesel Starting –Weapon Augmentation –Liquid Oxygen Reserves Original Cost/Actual Value –$400,000/$800,000

3. Safely convert compressor from 6 to 2 stages Safely install compressor Create a functional interface to log and trend data 1 4 32 1 – 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

4. Development Process

5. High Level Customer Needs and Engineering Specs Safety Considerations –Equipment List –Trainings and Procedures –70-95°F Room Temperature Maintenance Capabilities –24”-35” Access Space –30-45 ft 2 Storage Space –Tooling List –< 40 lbs. Manual Lifting –150-225 lbs. Assisted Lifting Installation of Compressor –8-19 Weeks from 12/3/07 –Acoustic Levels 75-100 dB –Vibrations 0.1-1.0 g/s –0 injuries –Room Structural Load =15,000 lbs (n f = 2.0) Compressor Revamp –6 to 2 Stages –25-37.5 hp –45-90.3 A –100+/-10 psi –Future Uses 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

6. 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

7. Installation MetricUnitsNeed #MarginalIdealNeed Met? Overall SafetyBinary1Yes Structural Load (n=1 or n=2)lbs17,500-10,00015,000-20,000Yes Mitigate Sound/VibrationsBinary5NoYes Future Uses ConsideredBinary4NoYes Tools to MaintainList2--Yes Lifting Capabilitylbs2150225Yes Space Per Sidein224/2435/24Yes Ventilate Exhaust SafelyBinary1Yes Accessibility Spaceft x ft57 x 4.57.5 x 5Yes Dual Function RoomBinary5NoYes Timeline on InstallSchool Weeks5198No All needs were accounted for in designs. Installation schedule delayed due to legal issues (ITAR). Donation compressor to be selected during the summer.

8. Concept Description: Installation Test Cell Layout Installation procedure and preparations Boulter Rigging Corporation: Contacted 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 A A

9. Structural Analysis 80 lb/ft 2 live load limit for original floor structure –Compressor exceeds (372 lb/ft 2 ) –2 W8X18 Steel Beams under the compressor to strengthen Dynamic conditions suitable with floor mount designs. Transporting the compressor –Redistribution of load over an area of at least 60 ft 2. Hire construction testing company for locating rebar

10. 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 mounts to 21 in 2 area 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

11. Revamp Designed removal of stages 3 - 6 from operation to decrease pressure to 100psi. Removal of unused cylinder heads, pistons, air piping and separators. Addition of counterweights, cover plates, and fake 6 th stage to replace pistons and heads. Reduction in HP and electrical needs from removal of stages 3 - 6. Mechanical power reduced from 68 HP to 25 HP. Electrical current reduced from 90.3 Amps to 38 Amps Reduction in cooling needs and removal of unused cooling system parts for increased cooling efficiency for new setup. Removal of unused cooling piping and heat exchangers. Calculated needed heat removal reduced from 29 Btu/sec to 11 Btu/sec. Due to reduction in heat generated from compression. Additional Adaptation of Condensate Drain system to floor drain. Approximate location of new air output fitting. MetricUnitsNeed #MarginalIdealMet Scaling of Pressurepsi3100 ± 25100 ± 10~100 Scaling of ElectricAmps390.345~37.5 Scaling of PowerHP337.525~24.3

12. Extra weight off to the sides for clearance of crosshead support. Interlocking halves to reduce bending moment on bolts. Area above crosshead was chosen for counterweights: – Availability of space. – Existing threaded holes. – Simple design. – Dresser-Rand success with this location in the past. Existing 6 th Stage Cylinder and Piston Revamp Concepts

13. Motor Characteristics Load %Current (Amps)K.W.RPMEff (%)PF (%)Torque (lb-ft) 188.958.3119195.486.1329 0.7568.243.6119395.883.5247 0.549.129.1119695.577.8165 0.2532.614.9119893.559.982 Original Design CFM90ft 3 /min p rated 75HP p actual 62HP V440Volts I original 90.3Amps Adiabatic HP # of Stages Theoretical Power (HP) Compressor Efficiency Actual HPLoad % Motor Efficiency Power Factor Torque (lb-ft) 633.770.54620.830.960.84272.15 213.230.5424.280.320.940.65106.49 Interpolation of Table Values Check using Formula Current Required # of StagesI (Amps) 674.5570.99 237.4736.56 Theoretical Heat of Compression StageT(°R)P (PSIA) C pair (Btu/lb*°F)qdot (Btu/sec) 1 in527.6714.5040.24 1 out744.6749.0040.2425.8 2 in554.6749.0040.24 2 out744.67109.5040.2425.08 3 in549.67109.5040.24 3 out779.67339.5040.2436.15 4 in549.67339.5040.24 4 out729.67774.5040.2424.82 5 in549.67774.5040.24 5 out714.671739.5040.2424.41 6 in549.671739.5040.24 6 out649.673014.5040.2412.68 average C pair 0.241 Total Heat Removal qdot 6 stages28.94Btu/sec qdot 2 stages10.89Btu/sec Theoretical Calculations

14. Communication -Part drawings package Counterweights Block off plates 6 th stage fake cylinder MetricUnitsNeed #MarginalIdealMet Drawings for PartsBinary6Yes DocumentationBinary6Yes

15. -Revamp Guide (22 pages) Communication -Documentation

16. -O&M Manual (50 pages text, 40 pages Appendices) Communication -Documentation

17. 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 & Representatives –Others provided where applicable Technical Information: –Safety Considerations –Procedures –DAQ Interface –Engineering Details –Appendices

18. 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

19. O&M Manual Procedures Installation Requirements –Formula Team –Senior Design Team –RIT –Boulter Rigging Company –Vibration Dampening Mounts Test Plans Startup & Shutdown Procedures

20. 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

21. O&M Manual Engineering Details Simple descriptions of major design changes –N30 Compressor –Test Cell Room 09-2329 References to locations of further details are provided where appropriate

22. 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

23. Objectives: To design an interface which future Senior Design teams can use to acquire and analyze data from sensors. Since the scope of this project is not to add sensors to the compressor, the goal of this sub function would be a ready interface as well as suggestions for devices (sensors and filters) later teams may want to use in order to gather data. Ideally a future team would simply have to add sensors to the compressor, convert the code to accept signals, and connect the sensors to a suggested data acquisition device which would relay data to the interface. 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. Interface

24. Interface Screenshots

25. Usability Testing TaskRound 1 (s)Round 2 (s)Total errorsTotal help requests Start up LabVIEW2200 Turn interface on21.6712.6702 View Graph of stage 22.67 00 Turn interface and LabVIEW off27.67933 Check crank angle after 20 iterations via the data file43.6711.6712 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. 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.

26. 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

27. 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

28. Contributions: Installation Boulter Rigging Company for installation Structural analysis as benchmark Room layout has been created Tools for maintenance have been provided Vibration Mounts –Identified for use on future project (adjust quantity and position) Room has been cleaned and prepared

29. 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

30. 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

31. Bill of Materials and Expenditures Total Spent $3007.40 Total Remaining $4992.60

32. Overall Projects Timeline

33. 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