1. 6/10/2015SYSTEMS LEVEL DESIGN REVIEW 1 HEALTH-MONITORING OF A RECIPROCATING COMPRESSOR MSD1 – P12453 SYSTEMS LEVEL DESIGN REVIEW

2. AGENDA 6/10/2015SYSTEMS LEVEL DESIGN REVIEW 2 Team and Project Member Introduction (1 min.) Project Introduction (4 min.) Customer Needs (5 min.) Concept Generation (15 min) Concept Selection (25 min) Risk Management (10 min) Next Steps (10 min) Q&A (10 min)

3. TEAM AND PROJECT MEMBERS 6/10/2015SYSTEMS LEVEL DESIGN REVIEW 3 TEAM: Project Manager: Markus Holzenkamp (ME) Project Engineers: Cody Anderson (ME) Robin Leili-Marrazzo (ME) CUSTOMER: Dr. Jason Kolodziej, ME Department, RIT Dr. Edward Hensel, ME Department, RIT SUPPORT: Project Guide:Bill Nowak (Xerox) Faculty Champion:Dr. Kolodziej (RIT) Sponsors:Scott Delmotte (D-R) James Sorokes (D-R) Britt Dinsdale (D-R)

4. PROJECT INTRODUCTION Reciprocating compressors Previous work Project scope 6/10/2015SYSTEMS LEVEL DESIGN REVIEW 4

5. Reciprocating compressors Reciprocating compressors use the back and forth motion of a piston connected to a crankshaft to compress the working fluid. In the case of this project we are working a single cylinder dual-action air compressor 6/10/2015SYSTEMS LEVEL DESIGN REVIEW 5

6. Previous work This project is a continuation of P11452. The group installed the Dresser-Rand compressor and the first basic sensors for monitoring beginning of life characteristics 6/10/2015SYSTEMS LEVEL DESIGN REVIEW 6

7. P12453 PROJECT SCOPE 6/10/2015SYSTEMS LEVEL DESIGN REVIEW 7 Understand the current state of the compressor Current sensors, DAQ capabilities Operation characteristics of reciprocating compressors Install and run ENVISION Condition monitoring system to be donated by Dresser- Rand Increase the current DAQ capabilities End Goal: Design, develop, and install effective health monitoring capabilities

8. CUSTOMER NEEDS Table of prioritized customer needs Function diagram 6/10/2015SYSTEMS LEVEL DESIGN REVIEW 8

9. TABLE OF PRIORITIZED CUSTOMER NEEDS 6/10/2015SYSTEMS LEVEL DESIGN REVIEW 9 PriorityNeed 1Learn RITDAQ capabilities and propose and implement improvements in code to generate p-v diagrams, time and frequency plots 1Propose and install possible additional sensors to measure stage pressures, stage temperature, bearing temperature (low priority) 2Install Envision System 3Select, install, and integrate Encoder 99Develop future undergrad/grad labs

10. RITDAQ ENCODER LABS Program Envision Install main bearing sensor Measure Pressure Temp Accel Measure accel Understand current capabilities Program RITDAQ Measure Velocity Choose an Encoder Mount Encoder Program Encoder Measure Crank Angle ENVISION Consider Ergonomics Mount Envision Install add. sensors Validate RITDAQ results Validate Envision Results Generate p-v diagrams Concepts needed Assistance from D-R FUNCTION DIAGRAM

11. CONCEPT GENERATION & SELECTION Engineering specs: Encoder/Envision House of Quality / Pareto of engineering specs Pugh concept selection Additional sensors 6/10/2015SYSTEMS LEVEL DESIGN REVIEW 11

12. ENGINEERING SPECIFICATIONS - ENCODER 6/10/2015SYSTEMS LEVEL DESIGN REVIEW 12

13. ENGINEERING SPECS - ENVISION 6/10/2015SYSTEMS LEVEL DESIGN REVIEW 13

14. HOUSE OF QUALITY 6/10/2015SYSTEMS LEVEL DESIGN REVIEW 14

15. PARETO OF ENGINEERING SPECS VS NEEDS 6/10/2015SYSTEMS LEVEL DESIGN REVIEW 15

16. PRIORITIZED ENGINEERING SPECS 6/10/2015SYSTEMS LEVEL DESIGN REVIEW 16

17. PUGH CONCEPT SELECTION FOR ENCODER 6/10/2015SYSTEMS LEVEL DESIGN REVIEW 17

18. POSSIBLE LOCATIONS FOR ENCODER 6/10/2015SYSTEMS LEVEL DESIGN REVIEW 18

19. ENCODER 6/10/2015SYSTEMS LEVEL DESIGN REVIEW 19 SideDiameter Flywheel2.720 in Oil Pump0.495 in Shaft Dimensions

20. PUGH CONCEPT SELECTION FOR ENVISION 6/10/2015SYSTEMS LEVEL DESIGN REVIEW 20

21. POSSIBLE LOCATIONS FOR ENVISION 6/10/2015SYSTEMS LEVEL DESIGN REVIEW 21

22. ADDITIONAL SENSOR TABLE 6/10/2015SYSTEMS LEVEL DESIGN REVIEW 22

23. POSSIBLE LOCATIONS FOR ADDITIONAL SENSORS 6/10/2015SYSTEMS LEVEL DESIGN REVIEW 23

24. POSSIBLE LOCATIONS FOR ADDITIONAL SENSORS 6/10/2015SYSTEMS LEVEL DESIGN REVIEW 24 S11, S12 S2 S13, S14

25. POSSIBLE LOCATIONS FOR ADDITIONAL SENSORS 6/10/2015SYSTEMS LEVEL DESIGN REVIEW 25 S6 S7, S8 S4, S5 S9, S10 S3

26. RISK MANAGEMENT 6/10/2015SYSTEMS LEVEL DESIGN REVIEW 26

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30. TOP RISKS 6/10/2015SYSTEMS LEVEL DESIGN REVIEW 30 Trip Hazard from wires Potential for injury Risk to equipment Noise in sensor signal Cannot use data Delay in equipment deliveries Project falls behind schedule

31. NEXT STEPS MSD 1 Schedule Detail Design Enabling Action Items 6/10/2015SYSTEMS LEVEL DESIGN REVIEW 31

32. MSD 1 SCHEDULE 6/10/2015SYSTEMS LEVEL DESIGN REVIEW 32

33. DETAILED DESIGN ENABLING ACTION ITEMS 6/10/2015SYSTEMS LEVEL DESIGN REVIEW 33 Markus: Select encoder (type, make, model, specs) Robin: Become familiar with Envision software (how to develop screens, add functionality) Cody: Consult with Dresser-Rand on how to best install sensors (sensor type, sensor location)

34. Q&A 6/10/2015SYSTEMS LEVEL DESIGN REVIEW 34