Student Version Operations
and Maintenance Manual
Contact Sheet for P09452: Compressor Installation,
Interface, and Education
First Name
Last
Major/Title
Team Role
Email
Cell Phone
Snehapriya
Rao
ME
Project Lead
snehapriyarao@gmail.com
917-628-5839
Edward
Budriss
ME
erb1260@rit.edu
267-210-6822
Alex
Scarangella
ME
ascarangella@gmail.com
914-806-6144
Edward
Wolf
CE
edward.wolf@gmail.com
203-648-3155
Anna
Cheung
ISE
Individual
Contributor
acc8828@rit.edu
518-588-7375
Margaret
Bailey
ME/Professor (Endowed
Chair)
Guide
mbbeme@rit.edu
585-475-2960
Marca
Lam
ME Professor
Consultant
mjleme@rit.edu
585-475-6871
Lawrence
Agbezuge
ME Professor
Consultant
lxaeme@rit.edu
585-475-2157
John
Wellin
ME Professor
Consultant
jdweme@rit.edu
585-475-5223
Amy
Hortop
ME Professor
Consultant
abheme@rit.edu
585-475-5628
Rizk
Sinada
Civil Instructor/
Project Manager RIT
FMS
Consultant
rnsppa@rit.edu
585-475-6716
Scott
Wolcott
CET Professor
Professional Engineer
Consultant
sbwite@rit.edu
585-475-6647
Dave
Hathaway
ME Operations Manager
Consultant
dlh6477@rit.edu
585-475-2184
Dave
Harris
Director, Environmental
Management
Consultant
ldh8974a@rit.edu
585-475-2060
Jim
Yarrington
Director of FMS
Consultant
jryfms@rit.edu
585-475-6932
Bobby
Colon
RIT Legal Counsel
Consultant
bobby.colon@rit.edu
585-475-6932
Individual
Contributor
Individual
Contributor
Individual
Contributor
Contact Sheet for P09452: Compressor Installation,
Interface, and Education
First Name
Last
Scott
Delmotte
Ray
McKinney
Mike
Bunce
Terry
John
Skip
McCarville
Kingham
Morrison
Major/Title
Manager Development
Engineering
Condition Monitoring
Specialist
Direct of Recruiting
PCB Piezotronics
Field Applications
Engineer
GE Energy
Optimization and
Control - Field
Application Engineer
Regional Manager
Team Role
Contact (Painted
Post)
Email
Cell Phone
SDelmotte@Dresser-Rand.com
607-937-2113
Contact (Olean)
RMcKinney@Dresser-Rand.com
716-372-4340
Contact (Olean)
MBunce@Dresser-Rand.com
716-375-4311
Consultant/Sales
tmccarville@pcb.com
Consultant/Sales
Consultant/Sales
john.kingham@ge.com
smorrison@prognost.com
609-238-3535
281-844-4685
Jason
Vigil
Professional Engineer,
Jensen Engineering, PC
Consultant
jasonv@jensenbrv.com
585-482-8130
Willis
Boulter
Boulter Rigging
Consultant
wboulter@boulter1.com
585-261-3102
Calculations and
Simulations
Cooling Loop Calculations & Specifications
Some of the heat of compression is transferred through the cylinder wall into four water
jacket channels. Each of these channels is identical. For the theoretical analysis of this
transfer, these channels were approximated as being round. The exact dimensions of theses
channels and other relevant geometries are unknown so approximate values were used and
may be changed as more precise information becomes available. The following is a list of
assumed dimensions and other parameters. The only value that is uncertain is the diameter;
the assumption is based on the known result.
Description
delta t in compressor
circum
number of jackets
K steel
K water
flow water
density of water
assumed D
mass flow rate
viscostiy of water
Cp water
Value
116.67
21.99
2.00
43.00
0.58
300.00
999.84
1.64
0.32
3.15E-04
4181.30
Unit
K
inch
#
W/m*K
W/m*K
GPH
kg/m^3
in
kg/s
Pa*s
KJ/Kg-K
Relevant Parameters:
Heat transfer (conduction + convection)
Nu  .023 Re 0.8 Pr .4
Re 
 DH
m
A
Heating fluid in round channel
Reynolds number equation
Heat transfer coefficient
Results:
Description
Re
prantle number water
Value
16290.36
7.00
Unit
#
#
nusselt number
h forced convection
Q
117.30
136.07
536.89
2147.55
7329.5956
#
BTU/ft^2*hr*F
W
W
BTU/Hr
delta t of water
10.00
o
F
From these results we are able to find a heat exchanger that will be able to handle the
required thermal load. The following components are suggested to make up the cooling
system.
Thermal Analysis
Thermal analysis was performed to approximate the amount of heat generated from
running the compressor. The heat of compression, heat from the inefficiencies in the
motor, the heat from free convection, and radiation off the surface of the compressor were
calculated. This document contains the calculations and results.
Heat of Compression Approximation
The heat of compression was approximated so that a heat exchanger could be sized for the
purpose of removing excess heat from the cylinder and compressed air. Assumptions and
other necessary data are listed below.
Assume:
Constant specific heat and specific heat ratio
Atmospheric pressure in the cylinder at BDC
Frictional losses are negligible
k
1.4
1.004
1.29
527.67
14.7
Cp,air
ρair
Tamb
Pamb
kJ/kg-K
kg/m^3
R
psi
Table 1: Parameters
Bore
Stroke
Vclearance
Disp.
Total Volume
6
5
3.3399057
0.0000547
141.37167
0.0023167
273.90761
0.0044885
Table 2: Cylinder Data
in
in
in^3
m^3
in^3
m^3
in^3
m^3
Temperature:
TComp.  TAmb.
Pout(psi)
51.25
 PComp. 

* 
P
 Amb. 
k 1
k
Tout(F)
293.9232349
Volumetric Flow Rate:
V
V2  Total1  VClear.
 P2  k
 
 P1 

V 2  V2 * RPM * 1 ft
3
1728in 3
Mass Flow Rate:
m   air VDisp.  VClearance.Exp.  * RPM
Heat Generated:



q  m c p T
51.25
Speed(RPM)
350
360
370
380
390
400
410
420
430
440
450
460
470
480
490
500
psi
Flow Rate(cfm)
22.3369
22.9751
23.6133
24.2515
24.8897
25.5279
26.1661
26.8043
27.4425
28.0807
28.7188
29.3570
29.9952
30.6334
31.2716
31.9098
Mdot (kg/min)
1.9910
2.0479
2.1048
2.1616
2.2185
2.2754
2.3323
2.3892
2.4461
2.5030
2.5598
2.6167
2.6736
2.7305
2.7874
2.8443
Heat gen.(kJ/min)
250.8944
258.0629
265.2313
272.3997
279.5681
286.7365
293.9049
301.0733
308.2417
315.4102
322.5786
329.7470
336.9154
344.0838
351.2522
358.4206
Heat gen.(BTU/hr)
14268.1225
14675.7831
15083.4438
15491.1044
15898.7650
16306.4257
16714.0863
17121.7470
17529.4076
17937.0682
18344.7289
18752.3895
19160.0502
19567.7108
19975.3715
20383.0321
Table 3: Calculated values for outlet pressure of 51.25 psi
P-V Diagram (Frame Side Cylinder)
60
Pressure(psi)
50
40
30
20
10
0
0
-25
25
50
75
100
125
150
Volume(in^3)
Figure 1: P-V Diagram (Frame Side Cylinder)
P-V Diagram (Outer Side Cylinder)
60
Pressure(psi)
50
40
30
20
10
0
-25
0
25
50
75
100
Volume(in^3)
Figure 2: P-V Diagram (Outer Side Cylinder)
125
150
Room Temperature/ Ventilation Calculations
The ventilation of the room is important for the comfort of the people in it. The heat that is
created by the compressor could potentially heat the room to unbearable temperatures if it
is not dissipated. The amount of ventilation in the room must remove the heat from the
compressor as well as the heat generated by the people operating the compressor and
performing lab experiments. The heat emitted into the room was previously calculated
from motor inefficiencies and black body analysis and was found to be approximately
3000 BTUs per hour. The table below shows all of the values that were needed to
approximately calculate the air flow required to keep the test cell temperature at an
acceptable level.
Description
Symbol
Value
Units
Temp of Machine Shop
Tshop
70
Fo
Max Temp.
Tmax
80
Fo
Heat From Compressor
Heat Gen. From People*
qcomp
met
3000
22
Avg. Exposed Skin Area
Askin
Number of People in Cell
npeople
Specific Enthalpy Exiting Air⁺
hin
26.2
BTU/lb
Specific Enthalpy Entering Air⁺
Specific Volume of Air (exiting)
Relative Humidity of the Shop
hout
1/
RH
29.8
13.71
60
BTU/lb
ft3/lb
%
BTU/hr
BTU/hr-ft2
2
ft2
15
#
*Metabolic heat generation for a person standing, relaxed
⁺From psychrometric chart negligible moisture added from people
Heat generated from people was calculated from the following equation:
q people  n people  met  Askin  15  22  2  660 BTU
hr
Rounding up to account for additional heat sources, the total heat generation is:
qtotal  qcomp  q people  4000 BTU
hr
Conservation of energy for our control volume (test cell) is used in the following equations
to calculate the necessary volumetric flow rate.
m in hin  qtotal  m out hout
m  m  V 
in
out
out
out
Vout  out hout  hin   qtotal
Vout 
qtotal
400013.71

 254CFM
 out hout  hin  29.8  26.2
This calculation is a good approximation and depends on the number of people that are in
the room operating the compressor, so the recommended ventilation flow rate should be
250-300 cubic feet per minute. The mechanical HVAC drawings of building nine indicate
that the test cell (room 09-2329) should be equipped with two 12 inch diameter ducts that
lead to exhaust fans on the roof (EF-31 and EF-32). Validation is required for duct
functionality and if it will meet the new compressor’s needs.
1st floor drawing showing existing 12" ducts
Fan schedule: See EF-31 and EF-32
Acoustic Analysis
Part of the safety aspect of operating and maintenance of the compressor is
ensuring that there will not be any acoustic damage or interference. The current planned
site for the installation is the test cell located in the machine shop. The test cell is currently
equipped with insulated door and wall.
It was assumed that with a full class, the doors will have to kept open for the class
to view the compressor when it is operating. Worst case scenario, the doors will be open, a
machine in the shop will be operating, and the compressor will also be operating.
Test
-
Used a sound level meter
o Mode: SPL
o Range: A Hi
o Response: Fast
Decibel value of the compressor when operating is approximately 85dB
Once compressor is installed, next team must verify that it operates at 85 db for
current calculations to be effective.
-
Table 1: Data from sound meter
Noise Dose  100(
8
tn 
2

c1 c 2
c
  ... n )
t1 t 2
tn
(L90)
5
Scenario 1, Class Time: Assuming door open, exposure to noises for an hour,
machine in shop is running, and compressor is running
Noise Dosage  100((
1
1
1
)(
)  ( ))
183
75.8
16
Noise Dosage  8.12
Dose < 50, hearing conservation is not needed when exposed for an
hour

Scenario 2, Maintenance: Assuming door open, exposure to noises for 8 hours,
machine in shop is running, and compressor is running
Noise Dosage  100((
8
8
8
)(
)  ( ))
183
75.8
16
Noise Dosage  64.9

Dose > 50, hearing conservation is needed when exposed for 8 hours
Maximum length of time exposed to multiple noise sources with out
hearing protection is 6 hours
Speech Interference Level
Using the A-weighted dB measure compared the rating to the graph in Figure 1 to
understand the furthest distance students can stand before background noises
interfere with communication.
Figure 1: Permissible distance between a speaker and listener
(http://www.nonoise.org/library/ane/pg47_ns5.gif)
With the compressor operating (85dB), the furthest the students can stand is 2ft
away before it is difficult to hear the professor or lab guide. This will need to be
taken into consideration when designing labs.
ANSYS Models
Test Cell
The test cell and surrounding rooms were modeled using SolidWorks. Dimensions
of the test cell and surrounding rooms were calculated using an AutoCAD file of building
9, provided by Facilities Management. This model was then imported into ANSYS to
perform structural and modal analysis. The model was constrained at the top of the walls
as well as basement walls. Using the built in ANSYS material list, the building was
defined to be construction grade concrete. The weight of the compressor was then applied
over the footprint of the skid on which it sits. The mesh was refined several to make sure
the model was accurately capturing true deformation and stress values. After two
iterations the deformation plateau at 0.00402in. ANSYS result as followed:
Figure 1: Deformation due to static load of compressor (top view) (MAX = .00402in)
Initial simulation for the testing of the static load of compressor revealed the floor itself
was not structurally acceptable to support the compressor. With these larger then
acceptable stress and deflection in the supporting surface our team worked with PE, Jason
Vigil. It was recommended that two I-beams be inserted under the final location of the
compressor as seen in figure 2.
Figure 2: Excerpt from PE report
I-beams were then modeled in Solid Works to the specifications laid out in the PE’s report.
The I-beams were designed to the dimensions for a W8 x18 Beam as specified. The initial
simulation had the beams located directly under the extremes of the skid. The material was
defined as structural steel and imported into ANSYS. The I-beams were constrained as
shown in figure 2 (at concrete beams and floor) and static loading simulations were
recompiled.
Figure 3: Deformation due to static load of compressor with I-beams under skid extremes
With the addition of the two I-beams (figure 1) the deflection of the floor decreased to
below 4 thousandths of an inch. Through communications with Jason Vigil, the results
achieved in the ANSYS modeling aligned with values he had calculate and deemed safe.
To determine if there could be any improvements by moving the I-beams more central,
towards the highest deflection and stress areas, the ANSYS models were rerun with the
beams moving inward in one-foot increments. As the I-beams were moved inward
resulting in the max deformation traveling from .0037in to .0029in (figures 4, 5, 6) at three
feet inboard of compressor skid. ANSYS results as follows:
Figure 4: Deformation due to static load of compressor, I-beams inboard 1 foot
Figure 5: Deformation due to static load of compressor, I-beams inboard 2 feet
Figure 6: Deformation due to static load of compressor, I-beams inboard 3 feet
In further discussions with Jason Vigil (PE), I brought up the results of the FEA. Through
talking to him he stated that while the skid will be static, it makes sense to move the beams
into the high stress areas. But when the compressor is operating there will be dynamic
forces in play and the beams located at the extremes of the skid will be better able to cope
and dissipate forces more uniformly.
Utilizing the same model, modal analysis was carried out to ensure that we did not
encounter any resonance issues within the structure. The model was constrained exactly as
from static analysis and simulations carried out. The frequency at which the compressor
operates is 8.33Hz. The first mode was found at 58.59 Hz. The second mode was found at
64.69 Hz. And third mode was found at 76.30 Hz. These can be viewed in figures 7, 8, 9.
ANSYS results as follows:
Figure 7: 1st mode vibrational response
Figure 8: 2nd mode vibrational response
Figure 9: 3rd mode vibrational response
In additional communications with our teams PE, Jason Vigil, he had arrived at natural
frequency of 8.5 Hz, which was based on the floor structure alone, a rather conservative
approach. With the addition of the walls to the model, a great deal of damping would be
expected, but with a value of 58Hz results seems high. This could be due to a number of
assumptions present in the model, such as empty rooms and perfect geometry. In
conversations with the PE, he stressed his case stating that the models used are often
grossly oversimplified to allow for the worst-case scenario. A more accurate natural
frequency would be a located somewhere between the 8.5 and results achieved through
modal analysis.
Compressor Skid
Using the documents provided by Dresser Rand, the skid was modeled in
SolidWorks and then imported into ANSYS. The skid was constructed from the material
IS 2062. The skid’s I-beams are of the type ISBM 150. For purposes of analysis, the skid
was constrained at each of its mounting locations, ten in total. The forces due to
reciprocation were then applied to the model at compressor mounting locations. The mesh
was refined several times in the areas of concern (front and rear mounting locations) to
ensure the model was accurately capturing true deformation and stress values. After
several iterations all values plateau ensuring accurate results. The moment due to
reciprocation induced a maximum deformation of .0054in (figure 10) and a maximum
stress of 7951.8psi (figure 11). ANSYS results as followed:
Figure 10: Total deformation of skid due to moment created by primary forces (MAX=.0054464 inch)
Figure 11: Stress due to forces generated from compressor.
Yield strength for material of skid (IS 2062) is 36,259psi providing a factor of safety
present in the skid of 4.56. A factor of safety two-three is commonly used, but since this
compressor is designed to operate in many different environments and have a fairly large
lifespan, the increased FOS represents that need of safety in the wide range of operational
environments.
Modal analysis was also carried out on the skid itself to see if the operational speed of the
compressor would have and damaging vibration affects on the skid. The model of the skid
was constrained identical to what was found in the static analysis. The 4th mode of
vibration occurring at 182.21 Hz was found to be in the same direction as would be found
from compressor operation (figure12). This mode is much higher than the operation speed
of the compressor, resulting in no concern for any safety issues with resonance, though a
slight pulse might be seen at this frequency from the accelerometer placed on the skid.
Figure 12: Modal deformation occurring at 4 th mode, (182.21 Hz) significantly above frequency of
compressor operation.
Installation Manual
Prior to the compressor being delivered to campus, the test cell should be fully prepped
and ready to receive the compressor. The test cell should be cleared of any unnecessary
storage, such as the Formula team’s old dynamometers, and fellow students’ design
projects. Additionally the following should be carried out:
Prior to compressor arrival
Structural reinforcements
Following the plans set forth by our designs teams PE, Jason Vigil, I-beams
should be installed as specified. Please review all documentation provided by Mr.
Vigil in appendix 1. Quotes have been obtained for contractor cost and can be
found in the budget. It is highly suggested to work with FMS to finalize the
contractor.
Figure 1: Excerpt from Jason Vigil’s (PE) recommendations
Additional Electrical Requirements
Prior to the compressor arriving on campus the test cell should be outfitted with
all the appropriate electrical supplies.
-220 volt 1 phase feed for the motor supply
-120 volt supply for the data acquisition system
-120 volt for ventilation and coolant pump requirements
A quote for the contracted work is located in the team budget. It is highly
suggested to work with FMS to finalize the contractor.
Cooling Water requirements
Prior to the installation of the compressor in the test cell, the chilled water supply
should be plumbed into the room for easy connection to the compressors cooling
system. The compressors cooling system will be installed after the compressor is
permanently located. See cooling system installation. It is highly suggested to
work with FMS to finalize the contractor.
Ventilation Requirements
Contingent on whether the drawings in the ventilation calculations are validated, a
single Greenheck GB-91 roof exhaust fan is more than ample. See ventilation
calculations. Given that at 250 CFM, a 12 inch round duct will only generate a
pressure drop of .015 inches of water per hundred feet. This is a very low
pressure, at which the GB-91 could exhaust over 800 CFM.
If the drawings are not confirmed and the GB-91 is not in place, then a similar,
but smaller, exhaust fan could be used. 1/8 horsepower would be plenty to meet
our needs.
If the 6 inch duct must be used, then the horsepower should be increased to 1/6 to
1/4 horsepower due to the much greater pressure drop of 0.5 inches of water per
hundred feet.
It is highly suggested to work with FMS if a contractor is needed.
**For any questions pertaining to the additions to the test cell please contact Dave Harris
or Dave Hathaway.
Scheduling Transportation
Boulter Rigging Company
Coordination between RIT, Boulter Rigging Corp., and Dresser-Rand will be
essential for smooth installation of compressor. Dresser-Rand will prepare the
machine for shipment to Boulter Rigging Corp. in Webster, NY. The compressor
will then be transported to RIT by Boulter and moved into the proper location.
Proper equipment will be used to ensure safety and clearance constraints are met.
Boulter Rigging Company will be responsible for delivering the compressor to
RIT as well as placing the compressor in its final resting place. The
recommended delivery path shown in figure 2 shows the best path for delivery. It
should also be noted that while the compressor is on the slab and not in its final
resting place, the load must be distributed over a minimum of 60sqft as stated in
Jason Vigils (PE) recommendations.
Figure 2: Installation path
-
45 feet of transportation across floor with basement underneath.
Loading bay area has foundation and can use fork lift until the entrance to the
old machine shop.
When being movied into location, the load must be distributed over 60 sqft
for adaquate load distribution.
Installation
Mounting
Once the compressor is moved into the test cell it should be located as described
in figure 3. The mounting holes should be marked and then compressor can be
moved back out of the room to allow for the drilling of the mounting holes. Once
the mounting holes are drilled and deemed adequate, the compressor can be
moved back to its final location and the process of securing it can begin.
Figure 3: Top View of Test Cell with Components and Locations
After the compressor has been placed atop its mounting holes measures should be
taken to ensure that the compressor is completely level. Using a level, shim the
bolt holes until the compressor is level. After achieving a level compressor
frame, the 12mm diameter grade 8 bolts can be pushed through to the bottom of
the slab. On the bill of materials, it was suggested to purchase 108 inches of
12mm grade 8 threaded rods. If using the rods, it must be cut to 8 inch length
prior to mounting. Using the appropriate washers, nuts and 6” x 6”x ¼” steel
plates the sequence of tightening can begin (100 ft/lbs). Please also refer to figure
1 section 3 for plate installation. The bolts should also be tightened after the
compressors first start up to ensure none have come loose.
Cooling System Installation
After the compressor has been installed, the cooling system can be outfitted to the
machine. The location of the heat exchanger is not fixed. Locate a suitable
location for the heat exchanger. Then the plumbing of the cold water supply to
the compressor can be carried out. Once the chilled water supplies are plumbed
and secured, the placement of the coolant storage tank should be determined,
remembering that a heating element will be placed within.
Figure 5: cooling loop diagram
The emersion heater probe should be installed into the storage tank. To do this,
an approximate 2” hold should be drilled in the side of the tank. This hole is to
allow for clearance between the plastic and the hot probe. Refer to the hazard
analysis for possible dangers and mitigation. Next a stainless steel plate should be
fabricated to allow for the attachment of the probe and for easy attachment to the
storage tank. Once the probe has been installed to the tank, the tank can be
secured within the room. Final plumbing of the cooling system can be carried
out. Refer to figure 5 for cooling loop layout.
Sensor Install
There are numerous sensors that will be installed onto the compressor. The scope
of this project is to allow for flexibility in the location and configuration of all
sensors. As laboratory experiments evolve, it may become necessary to add or
move additional sensors to different locations. The following information includes
sensor locations and manufacturers’ preferred installation methods for the sensors
to be used in the DAQ system.
Sensor Placement
The following locations are the preliminary mounting points for the sensors
specified in Table 1.
A
B
D
C
Figure 6 - Top view Schematic of Dresser-Rand Compressor
Position
A
A
B
C
Sensor
X-axis Velocity
X-axis Accelerometer
Inner Bore Pressure
Z-axis Accelerometer
Model #
PCB VO622A11
PCB 623C00
PCB 102A21
PCB 623C00
Mounting
Stud/Magnetic Mount
Stud/Magnetic Mount
Bore Hole
Stud/Magnetic Mount
D
D
Y-axis Velocity
PCB VO622A11
Y-axis Accelerometer PCB 623C00
Table 1 - Sensor Placements of Figure 1
Stud/Magnetic Mount
Stud/Magnetic Mount
J
K
E
I
F
G
H
Figure 7 - Air and Cooling Water Schematic
Position
E
F
G
H
H
I
I
J
J
K
Sensor
Inlet Air Pressure
Tank Air Pressure
Tank Air Temperature
Model #
PCB 101A05
PCB 102A21
Omega RTD-NPT72-E-DUAL-MTP
Outlet Air Temperature
Omega RTD-805
Air flow meter
Omega FTB-936
Water Inlet Flow Rate
Omega FV101
Water Inlet Temperature
Omega FV101
Outlet Water Temperature Omega FV101
Outlet Water Flow Rate
Omega FV101
Inlet Air Temperature
Omega RTD-805
Table 2 - Sensor Placement of Figure 2
Mounting
Stud Mount
Bore Hole
Bore Hole
Adhesive Mount
Pipe Fitting
Pipe Fitting
Pipe Fitting
Pipe Fitting
Pipe Fitting
Adhesive Mount
L
Figure 8 - Frame Oil Schematic
Position
L
L
Sensor
Model #
Oil Temperature
Omega PR-12
Oil Pressure
PCB 101A05
Table 3 - Sensor Placement of Figure 3
Mounting
Pipe Fitting
Bore Hole
Adhesive Mount
Adhesive mounting bases are recommended to prevent an adhesive from
damaging the sensor base or clogging the mounting threads. Below is a table of
PCB’s suggested mounting adhesives.
Magnetic Mount
Magnetic mounts are to be used for temporary sensors on a magnetic surface. A
thin layer of silicone grease should be applied between the sensor and magnetic
base, as well as between the magnetic base and the structure.
Stud Mounting
This type of installation is to be used for the permanent installation of sensors.
First, grind or machine on the test object a smooth, flat area at least the size of the
sensor base, according to the manufacturer's specifications. Then, prepare a
tapped hole in accordance with the supplied installation drawing, ensuring that the
hole is perpendicular to the mounting surface. Install accelerometers with the
mounting stud and make certain that the stud does not bottom in either the
mounting surface or accelerometer base. A thread-locking compound may be
applied to the threads of the mounting stud to guard against loosening.
Screw Mounting
Like a stud mount installation, screw mount installations are to be used on thinwalled surfaces. A cap screw passing through a hole of sufficient diameter is an
acceptable means for securing the accelerometer to the structure. A thin layer of
silicone grease at the mounting interface ensures high-frequency transmissibility.
Source: http://www.pcb.com/techsupport/tech_accel.php
DAQ Install
A key component to the educational application of this project will be with the use of the
Data Acquisition system. The diagram below shows what will ultimatley be produced in
the succeding projects.
System-level overview of the compressor Data Acquisition System
At this point, all the sensors should be mounted on the compressor. It should also be
noted that signal conditioners and connector cables for the sensors need to be specked out
and purchased. At the time of this document’s publication, the total project budget, DAQ
unit, and cable lengths are subject to change. These variables should be clearer once the
compressor arrives on campus. Given the relationship with Dresser-Rand, it is possible
that a NI PCI-4474 may be donated. For that reason, it is assumed that this will be the
primary 8-channel DAQ for the LabView computer.
Ray McKinney from Dresser-Rand in Olean, NY has been the primary contact for
designing the data acquisition unit. From his contacts, he is currently investigating if he
can get the temperature and pressure sensors donated for the project. He also might be
able to get a PCI-4474 card either donated from National Instruments or from a customer
recall site in Israel. Additionally, Ray has been working to get replacement sensors for
the Omega products. We will be working with him in the future to see if these sensors
can be swapped out for Bently Nevada Solutions.
High-level installation steps:
1. Install as many sensors on the compressor as the budget allows.
2. Install the NI PCI-4474 card (or final DAQ) onto the LabView Computer.
3. Run and secure all cabling to sensors/signal conditioners to the LabView
Computer.
4. On the LabView Computer, configure the LabView Compressor Project to accept
all the sensors. All the random number generators will have to be replaced, and all
the sensors will need to be calibrated.
a. IP: 129.21.243.89 LOGIN: Dave PASSWORD: P09452
5. Test the DAQ to ensure it is measuring the correct information.
-
-
Bulleted Installation Procedure:
Formula Team has vacated room to new area to secure their stock materials:
o Temporary movement to another cell. Room should be vacated beginning
the quarter prior to compressor arrival to allow for all contracted work to
take place.
o Need to have clear access to floor and surrounding walls of Test Cell.
o Engine Dyno will be removed from the back 4 feet of the room.
Senior Design Team will prepare for the compressors arrival:
o Order and purchase any items used in the installation process.
 Boulter, storage racks, tools, sensors, etc.
 Mounting hardware and plates.
 Structural reinforcement by general contractor before compressor
is installed.
 Electrical services before the compressor is installed.
 Cooling pipe installation services by general contractor before
compressor is installed
 Orders should go out as soon as possible after approval.
o Provide necessary information to Boulter:
 On schedule and route for transportation.
 Materials necessary for install.
 Structural concerns and requirements.
 Provide structural engineer’s analysis and suggestions.
o Prepare the room for compressor:
 Clean up and create a sustainable work environment.
 Ensure unrestricted access to all areas of the room and input
supplies.
 Mark and drill the required holes needed for mount installation
when compressor is placed in final position.
 Identify and mark the location of the control panel and emergency
stop.
 Room must be vacated of all materials to give sufficient room to
rigging company.
 Ensure that path to the room is clear of any obstructions.
o After Installation
 Assemble and install storage rack, desk, and work bench in test
cell
 Placement of these items should follow the Test Cell
Layout.
 Upon completion, these items will be used for storage of
equipment.
 Place computer, DAQ, tools, spare parts, etc. in proper locations
 Provide all safety material in the test cell.
 Post signs and stickers
 Place necessary safety equipment in the room (see safety
document)


-
Install and hook up cooling system
 Coolant tank, heat exchanger, heater, valves and piping
Install and hook up sensors and data acquisition unit
 See sensor install for specifications and locations.
Preparations by Boulter for relocation:
o Transport machine from Dresser-Rand to Boulter Rigging Company
 Provide sufficient time for Boulter to know machine.
 Verify that the correct equipment will be used and is available.
o Transport machine from Boulter Rigging Company to RIT machine shop
loading bay.
o Upon arrival to RIT:
 Unload from truck with fork lift.
 Forklift will place machine on skates in new addition of shop.
o Use skates to transport machine across the machine shop
 Use no less than 4 carts to ensure sufficient load distribution
 Locate the carts underneath machine with proper access.
o Place machine in final location with mounts over bolt holes in floor.
 Place machine as precisely as possible with limited loads being
seen by floor.
Safety Manual
Prior to installing, operating, or performing maintenance on the compressor, review all
safety procedures and operating manual. Be aware of all reciprocating components,
electrical hazards, pinch-points, rotating parts, and pressurized equipment. Once the
compressor is operational, there are normal daily operating procedures that should be
maintained.
Observe All Hazard and Warning Labels
PERSONAL PROTECTITIVE EQUIPMENT
Always Wear the Appropriate Safety Gear

Safety glasses or goggles

Gloves

Ear protection
TORQUING SAFETY POINTS
These Are Unsafe Tool Uses!
 Never torque any fasteners or flanges on a unit that is running or pressurized
 Use correct torquing procedures
 Use correct size / range torque wrench
 Do not use cheater bars or pipes on wrenches
 Use thick wall sockets, no chrome sockets
 Make sure you have good support to back up hydraulic wrenches and torque
multipliers
LIFTING SAFETY
Use Your Legs, Spare Your Back

Know the weight of the item you are lifting

Bend at the knees (not your waist) and lift using your
legs

Ask a co-worker to help with the load

Use a crane, hoist, fork truck etc. if in doubt
Proper Crane and Sling Use
 Inspect all lifting straps and chains for
cuts or other damage before using
 Verify lifting capacity of cranes or chain
falls
 Check lifting eye bolts for bent or
damaged thread section
Use Proper Swivel Eye Bolts
LOCKOUT, TAG-OUT ELECTRICAL POWER
 Before performing any work on the unit ensure
that the electrical power has been de-energized
and locked out at the breaker panel to prevent
accidental electrical shock or start up of the unit
Normal Daily Operating Procedures
•
Check the oil level
•
Check discharge pressure is zero
•
Turn on the cooling water
•
Start the compressor unloaded
•
Select the compressor load: 50% or 100%
• Do this within 10 minutes to prevent overheating
•
Compressor discharge pressure will rise to the setting of the backpressure valve
(typically around 35 psi).
Normal Operation

Depressurize Before Valve Cover Removal

Be careful where you place your hands and finger when tightening the piston rod
jam-nut with hammer wrench
Typical Reciprocating Compressor Cylinder Assembly
Cylinder Pinch-Points
Running Gear Pinch-Points




Pinch-Point Electric Motor Drive Belts
Pressurized Valve Cover
Hot Discharge Temperatures: Compressor Cylinder & Discharge Bottle
Electric Motor Shock Hazard
Hazards Analysis
To ensure the safety of faculty and students during the use of the compressor, a
hazard analysis was performed. The team systematically went through the different sub
components of the compressor and identified possible catastrophic failures.
The next team should review the hazard analysis, to ensure that there were not
any areas overlooked. Each hazard should also be reassigned to the new team members
to cover suggested mitigation or to create a new strategy.
Educational Labs
Investigation: Compressor P-V Diagrams & Efficiency
This investigation explores the concepts of isentropic compression in a Dresser-Rand
single piston, double acting, reciprocating compressor. 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. This can be compared with the
theoretical pressure vs. volume diagram. Assuming adiabatic compression and negligible
pressure drop through the valves, a theoretical p-v diagram can be generated. Do this by
charting and plotting 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. Some important values are tabulated below and may be of use. The theoretical
P-V diagram should look similar to the one shown below.
VTDC,Outer
2.545
VTDC,Frame
0.795
VBDC,Outer
143.916
VBDC,Frame
142.167
P-V Diagram (Outer Side Cylinder)
60
Pressure(psi)
50
40
30
20
10
0
-25
0
25
50
75
100
125
150
Volume(in^3)
Assignment
Before starting the compressor, make yourself aware of all startup procedures and take all
the necessary safety precautions. Before recording any data, be sure to run the
compressor for a minimum of 5 minutes to ensure that the compressor has had time to
reach steady state. Using the Labview interface, locate the thermal fluids lab 1 tab and
begin logging pressure and volume data by pressing “Log Data” and saving the values in
a .txt file format. The log data feature will automatically log data for a limited amount of
time due to the large number of samples per second. These values can be imported into
excel and plotted to create the experimental p-v diagram.
Create a formal report section comparing experimental data with theoretical predictions,
following the guidelines and specific topics below.
 Fully documented calculations for theoretical values. We will assume that the air
entering the cylinder is at atmospheric pressure when the piston is at bottom dead
center. Compute enough values to produce a nice smooth curve. When
performing calculations, make sure that valve-opening pressure is identical to the
experimental outlet pressure and the pressure in the cylinder is constant after the
valve is opened. Be sure to incorporate the clearance volume in your calculations.
State all assumptions.
 Generate one chart with both theoretical and experimental plots.
 Discuss the general agreement between the measured pressure curve, and the
theoretical predictions. Do they agree within the experimental errors? If not, what
else might account for the discrepancies (other than simple human error)?
Compute average error in pressure over one cycle. Were our assumptions valid?
Explain.
 Using the information presented on the compressor interface calculate the
efficiency of the compressor. What are some causes for the inefficiencies present
in compressor?
Note:
The Lab developed should be tested once the DAQ and compressor are operational to
ensure they are suitable for student labs. This means having a Thermal Fluids lab
professor as well as students test the lab and correct or modify any necessary aspects.
Investigation: Vibration of Compressor Skid
The single stage, dual acting compressor applies an oscillatory load on the skid
that it is attached to. Refer to Figure 1 to see a diagram of this compressor. For this lab,
use the accelerometer attached to the skid to acquire displacement data. With the data
produce a spectral plot. After recording the frequencies shown by the spectral plot
compare them to the ANSYS model developed by the Senior Design Team and your own
model. Also record the maximum deflection.
Figure 1: Single Stage Dual Acting Compressor
ANSYS Modeling Results
Using the documents provided by Dresser Rand, the skid was modeled in
SolidWorks and then imported into ANSYS. The skid was constructed from the material
IS 2062. The skid’s I-beams are of the type ISBM 150. For purposes of analysis, the
skid was constrained at each of its mounting locations, ten in total. The forces due to
reciprocation were then applied to the model at compressor mounting locations. The
mesh was refined several times in the areas of concern (front and rear mounting
locations) to ensure the model was accurately capturing true deformation and stress
values. After several iterations all values plateau ensuring accurate results. The moment
due to reciprocation induced a maximum deformation of .0054in (figure 2). ANSYS
results as followed:
Figure 2: Total deformation of skid due to moment created by primary forces (MAX=.0054464 inch)
Modal analysis was also carried out on the skid itself to see if the operational
speed of the compressor would have and damaging vibration affects on the skid. The
model of the skid was constrained identical to what was found in the static analysis. The
4th mode of vibration occurring at 182.21 Hz was found to be in the same direction as
would be found from compressor operation (figure 3).
Figure 3: Modal deformation occurring at 4th mode, (182.21 Hz) significantly above frequency of
compressor operation
Instructions
1. Take deflection data from the accelerometers attached at the point where the body
of the compressor is bolted to the skid. These are the points where you will see
maximum deflection due to vibratory load.
2. Generate a spectral plot wih LabVIEW
3. Compare these results with you model as well as the ANSYS results show above.
4. Explain your results
Note:
The Lab developed should be tested once the DAQ and compressor are operational to
ensure they are suitable for student labs. This means having a Vibrations lab professor as
well as students test the lab and correct or modify any necessary aspects.
Test Plans
Test Plan – Usability Testing



6-8 student test subjects, with 2nd to 3rd year engineering/computer abilities.
1-2 faculty test subjects.
5-10 minute overview of the project and compressor.

Tasks to be completed by each test subject:
o Start up Compressor Interface
o Turn program on
o View Graphs Screen and see if they can easily interpret information on the
screen
o Turn program off
o Close out Compressor Interface
o Access excel file

Assessment Factors:
o Thought process of subject as they are performing actions
o Frequency of help requests
o Number of errors made in execution of instructions (ie Laboratory)
o Time to complete task
o Intuitiveness/Navigation/Aesthetics/comments

Other situations to test:
 Run program with the previous data file open while the new instance is set
to save to the same file name
 Run program with previous data file open while the new instance is set to
save to a different file name
Prior to First Run
E-Stop
1) Ensure power is connected to the control unit by using a voltmeter to check power
supply to the control unit.
2) Press the E-Stop button located in the front of the room.
3) Ensure that the control unit has lost power.
4) Reset the circuit breaker.
5) Press the E-Stop button located in the back of the room.
6) Ensure that the control unit has lost power.
7) Reset the circuit breaker.
8) Press the E-Stop button located outside of the room.
9) Check that the control unit has lost power.
10) Reset the circuit breaker.
Lock-Out Tag-Out for Control Panel
1) Pull down the power lever to shut down the main circuit breakers.
2) Use the lock-out tag-out lock to ensure the lock-out lever is restricted from moving.
3) Turn on the control panel.
4) Use a multi-meter to check that the control panel is not receiving power.
5) Turn off the control panel.
6) Un-lock the lock-out lever.
7) Pull the power lever up to return power to the main circuit breakers.
Measure and Adjust Machine Level
1) Check that the compressor is fully installed on the vibe-prevention mounts.
2) Place a level on the base of the compressor.
3) Check that the compressor is level. If it is leveled, no further adjustments are
necessary.
4) If it is not, determine the appropriate mount for adjustment.
5) Lift the compressor off of the adjustable mount.
6) Use a wrench to adjust the mount.
7) Return the compressor into the mount.
8) Check that the compressor is level. If it is leveled, no further adjustments are
necessary.
9) If it is not level, repeat steps 5-8.
Air Flow Results
1) Obtain the test results for the air circulation from Dave Hathaway.
2) Ensure that the room air will be fully circulated at least every 15 minutes.
Miscellaneous Room Preparations
1) Use a simple lamp, or any other safe electronic device, to test the room’s wall outlets.
2) Use a laptop and spare Ethernet cable to test the internet connectivity of the CAT-5
connection outlet located in the front of the room.
During First Run
E-Stops
1) Start the compressor.
2) Press the E-Stop button located in the front of the room.
3) Ensure that the compressor has lost power.
4) Reset the circuit breaker.
5) Start the compressor.
6) Press the E-Stop button located on the control panel.
7) Ensure that the compressor has lost power.
8) Reset the circuit breaker.
9) Start the compressor
10) Press the E-Stop button located outside of the room.
11) Check that the compressor has lost power.
12) Reset the circuit breaker.
Visual Safety and Maintenance Checks
1) Record all noticeable areas of moving parts that are potential safety hazards or pinch
points.
2) Record any unexpected noises that occur.
Lock-Out Tag-Out for Compressor
1) Pull down the power lever to shut down the main circuit breakers.
2) Use the lock-out tag-out lock to ensure the lock-out lever is restricted from moving.
3) Turn on the compressor.
4) Use a multi-meter to check that the compressor is not receiving power.
5) Turn off the compressor.
6) Un-lock the lock-out lever.
7) Pull the power lever up to return power to the main circuit breakers.
Room Sound Levels
1) Obtain a Sound Level Meter from the Ergonomics Lab in the IE Department.
2) Record a sound measurement at a distance of 1m from the compressor.
3) Record a sound measurement at a distance of 1m from room 09-2329 with opened
doors.
4) Record a sound measurement at a distance of 10m from room 09-2329 with closed
doors.
5) Ensure all readings are within the safety requirements.
Room Temperature
1) Obtain a type K thermocouple attachment and a multi-meter from John Wellin or a
Thermo-fluids lab.
2) Obtain a temperature reading from 10m outside of room 09-2329 as a baseline
ambient temperature value.
3) Stand in the center of the front half of room 09-2329, and record the ambient
temperature value every minute for 12 minutes (to provide 3 cycles of the air exhaust
system).
4) Stand in the center of the back half of room 09-2329, and record the ambient
temperature value every minute for 12 minutes (to provide 3 cycles of the air exhaust
system).
Vibrations
1) Move outside the Test Cell (09-2329), shutting the door on way out.
2) Face the door to the Test Cell (one meter away from center) and make observations
on any vibrations felt.
3) If vibrations can be felt through floor (step 4), move back from Test Cell one meter at
a time until vibrations are no longer felt.
4) Repeat step 3 for all directions (right and left) and record values to create circle of
influence.
5) Make final observations about effects from vibrations of the compressor.
Removal and Re-install of Parts
Lock-Out Tag-Out for Compressor
1) Pull down the power lever to shut down the main circuit breakers.
2) Use the lock-out tag-out lock to ensure the lock-out lever is restricted from moving.
3) Turn on the compressor.
4) Use a multi-meter to check that the compressor is not receiving power.
5) Turn off the compressor.
6) Conduct any necessary part removals and re-installs.
7) Un-lock the lock-out lever.
8) Pull the power lever up to return power to the main circuit breakers.
Lifting Capabilities
1) Bring the lift crane into the test cell room with the compressor.
2) Ensure that the lift crane can fully access the compressor.
3) Check that manual lifting is possible for any areas that are not accessible by the lift
crane.
Planning Documents
Finalized Bill of Materials
Current Budget and Expenditures
Dresser - Rand Appointed Budget
Date
Area Concerned
P08452
14-Dec-07 Project Management
11-Jan-08 Project Management
18-Jan-08 Project Management
18-Jan-08 Project Management
18-Jan-08 Project Management
18-Mar-08 Project Management
28-Mar-08 Material
28-Mar-08 Project Management
29-Mar-08 Project Management
30-Mar-08 Project Management
31-Mar-08 Project Management
9-May-08 Project Management
9-May-08 Bill of Materials
16-Apr-08 Project Management
21-May-08 Project Management
21-May-08 Project Management
Structural Estimate
P09452
16-Jan-09 Project Management
16-Jan-09 Project Management
13-Feb-09 Project Management
13-Mar-09 Project Management
13-Mar-09 Project Management
6-Apr-09 Project Management
17-Apr-09 Project Management
Description
Olean Visit
Lunch with Scott
Van to Painted Post
Van Fuel
Meals
Mileage to Dr. Bailey
BOM Expenditures
Van to Painted Post
Van Fuel
Lunch with Dresser-Rand
Mileage to Dr. Bailey
Lunch with Dresser-Rand
Final Total of Purchased Parts
Final Lunch
CMVA Registration
CMVA Hotel Expenses
PE Consulting Work
Painted Post Visit - Gas
Painted Post Visit - Lunch
RIT Review - Lunch
Painted Post Safety Training - Gas
Painted Post Safety Training - Lunch
Olean, Sensor Review - Gas
RIT Review - Lunch
Total Spent
Amount Remaining
$16,000.00
Cost
$150.00
$40.00
$60.00
$23.51
$38.88
$124.42
$127.31
$60.00
$32.00
$106.95
$95.70
$77.40
$2,043.39
$113.55
$460.00
$195.00
$1,800.00
$22.44
$83.82
$51.11
$58.23
$48.75
$20.00
$49.21
$5,881.67
$10,118.33
Scope of Supply
A scope of supply document was created based off the hazard analysis findings. With the
ability to customize portions of the compressor, the scope of supply communicated RIT’s
present specific needs to Dresser Rand.
-
Relief Valve repositioned downward
-
E-stop
o Incorporate into control panel
-
Bore Hole
o Need two holes placed in the compression chamber (pressure transducer)
o Need a hole placed in the discharge pulsation vessel (pressure sensor)
o Need a hole placed in the oil sump (temperature sensor)
-
Handles Welded on to access panels
-
Clear strategically placed access panels
o Purpose is to view components in motion
o Suggested material – Lexan
-
Replace 480V 3 phase motor with 220V 1 phase motor
Finalized QFD
The quality function deployment assisted in the planning of engineering metrics,
identifying customer needs, and tracking progress during the design phase.
9
3
9
9
9
9
9
Good
A
A
A
A
3
9
9
A
A
9
A
A
3
3
3
3
9
9
9
9
9
A
3
A
A
A
A
A
3
3
Good 5
4
3
2
Poor 1
Raw
score
A
297
243
270
297
252
189
189
486
513
324
Relative
Weight
6%
7%
8%
7%
5%
5%
13%
13%
8%
9
9
8%
9
9
Binary - Have Required Documents
9
Binary - Have Required Documents
9
Binary - Research sensors for lab and health monitoring
9
Obtain List of Collected Variables
9
9
243
8 Hz < x Hz < 60 Hz
9
9
6%
75 dB < x < 100 dB
A
A
108
35 in < x in < 48 in
A
A
A
A
Obtain List of Tools
9
5
Repair and Upkeep Tools
3
3
3
3
3
3
4
Lab Procedure Document
3
9
3
Installation Documentation
9
3
3
Sensors
Noise
9
DAQ
Temperature (Discharge)
3
9
Vibration
Storage Area
9
9
1
3
9
3
Customer Perception
459
750 lbs < x lbs < 1500 lbs
+
3%
Technical Benchmarking
+
up dwn dwn dwn
Engineering Metrics
12%
Obtain Equipment on List
Technical Targets
Binary - Provide Ventilation System
Customer Requirements
Safety
Account for total install safety and threats9
9
9
Consider safety (operation, start up, and shut
9 down)9
Provide accessibility procedures for components
9
3
Use proper safety equipment when working
9 on machine
9
3
Consider impact of vibration and sound 9
9
Ensure environment around room remains9 safe
3
Maintenance Capabilities
Means to achieve lifting
9
9
Handle mechanical and electrical issues 9
Ensure proper safety equipment and guidelines
9
are used 3
Provide storage and work space for maintenance
3
9
Install
Follow a detailed, precise timeline of the 9process
Ensure proper safety measures are taken 9
9
3
Consider the layout space around the machine
9
9
Prevent disruption of classroom environments
9
by machine
Future Uses
Include basic setup of interface for future 9health monitoring
Account for use of data acquisition equipment
3
Consider possibility of future modifications
3 for health monitoring
Prepare labs pertinent to coursework
9
Dresser-Rand Involvement
Keep up frequent discussions
9
Provide sufficient and ample documentation
9
+
+
+
+
3
up
+
Poor
up
+
2
+
Correlation Codes
+ + Very Positive
+ Positive
- Negative
- - Very Negative
1
+
NO INPUT IN THIS AREA
70° F < x° F < 95° F
Exhaust Ventilation
Safety Equipment
Customer Weights
Preferred
--
Accessability Space per Side
+
+
-
30 sqft < x sqft < 60 sqft
+
++
+
Lifting Capability
Safety Equipment
Exhaust Ventilation
Lifting Capability
Accessability Space per Side
Storage Area
Temperature
#REF!
Noise
Vibration
DAQ
Sensors
Installation Documentation
Lab Procedure Document
Repair and Upkeep Tools
A: Current 1-stage ESH
A
A
A
A
A
A
A
A
A
A
A
A
Appendix