Compressor Installation & Monitoring System for RIT Labs

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

2. 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

3. 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

4. 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

5. 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

6. 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

7. 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

8. Installation – Transportation/Mounting Work with Boulter Rigging Dresser-Rand → Boulter Rigging → RIT 45’ of transportation through Building 09 Load must be distributed over 60ft2 using skates Mount using shim, 12 mm grade 8 bolts, nuts, and steel plates

9. 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

10. Installation – Cooling Loop

11. Installation - Acoustics Lab Situation Extended Maintenance 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

12. 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

13. Installation – Sensors

14. Installation – Sensors

15. 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

16. 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)

17. 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.

18. 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

19. 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

20. 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