HEALTH-MONITORING OF A RECIPROCATING
COMPRESSOR
MSD1 – P12453
SYSTEMS LEVEL DESIGN REVIEW
SYSTEMS LEVEL DESIGN REVIEW
4/13/2015
1
AGENDA
•
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)
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TEAM AND PROJECT MEMBERS
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)
SYSTEMS LEVEL DESIGN REVIEW
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Reciprocating compressors
Previous work
Project scope
PROJECT INTRODUCTION
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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
SYSTEMS LEVEL DESIGN REVIEW
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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
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P12453 PROJECT SCOPE
•
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 DresserRand
•
Increase the current DAQ capabilities
•
End Goal: Design, develop, and install effective health monitoring capabilities
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Table of prioritized customer needs
Function diagram
CUSTOMER NEEDS
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TABLE OF PRIORITIZED CUSTOMER NEEDS
Priority Need
1
Learn RITDAQ capabilities and propose and implement improvements in
code to generate p-v diagrams, time and frequency plots
1
Propose and install possible additional sensors to measure stage
pressures, stage temperature, bearing temperature (low priority)
2
Install Envision System
3
Select, install, and integrate Encoder
99
Develop future undergrad/grad labs
SYSTEMS LEVEL DESIGN REVIEW
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FUNCTION DIAGRAM
Install add.
sensors
Measure
Pressure
Assistance from D-R
Temp
Accel
Install main
bearing sensor
Validate Envision Results
RITDAQ
ENVISION
Program
Envision
Consider
Ergonomics
Validate RITDAQ
results
Understand current
capabilities
ENCODER
Choose an Encoder
Program RITDAQ
Measure
accel
Mount Encoder
Mount
Envision
Measure Velocity
Program Encoder
Measure Crank Angle
LABS
Concepts needed
Engineering specs: Encoder/Envision
House of Quality / Pareto of engineering specs
Pugh concept selection
Additional sensors
CONCEPT GENERATION & SELECTION
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ENGINEERING SPECIFICATIONS - ENCODER
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ENGINEERING SPECS - ENVISION
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HOUSE OF QUALITY
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PARETO OF ENGINEERING SPECS VS NEEDS
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PRIORITIZED ENGINEERING SPECS
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PUGH CONCEPT SELECTION FOR ENCODER
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POSSIBLE LOCATIONS FOR ENCODER
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ENCODER
Shaft Dimensions
SYSTEMS LEVEL DESIGN REVIEW
Side
Diameter
Flywheel
2.720 in
Oil Pump
0.495 in
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PUGH CONCEPT SELECTION FOR ENVISION
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POSSIBLE LOCATIONS FOR ENVISION
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ADDITIONAL SENSOR TABLE
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POSSIBLE LOCATIONS FOR ADDITIONAL
SENSORS
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POSSIBLE LOCATIONS FOR ADDITIONAL
SENSORS
S11,
S12
S13,
S14
S2
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POSSIBLE LOCATIONS FOR ADDITIONAL
SENSORS
S9,
S10
S4,
S5
S6
S7, S8
S3
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RISK MANAGEMENT
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TOP RISKS
•
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
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MSD 1 Schedule
Detail Design Enabling Action Items
NEXT STEPS
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MSD 1 SCHEDULE
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DETAILED DESIGN ENABLING ACTION ITEMS
•
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)
SYSTEMS LEVEL DESIGN REVIEW
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Q&A
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