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Design Review
April 17, 2009Team Members:
Snehapriya RaoEdward BudrissEdward WolfAlex ScarangellaAnna Cheung
Faculty Guide: Dr. Margaret Bailey
Table of Contents
ANSYS Models....................................................................................................................3
Cooling Loop Calculations & Specifications.....................................................................9
Installation/ Test Cell.......................................................................................................12
Final List of Sensors.........................................................................................................17
Sensor Installation...........................................................................................................18
Test Plan – Usability Testing...........................................................................................22
Prior to First Run.............................................................................................................23
Miscellaneous Room Preparations..................................................................................25
During First Run..............................................................................................................25
Removal and Re-install of Parts......................................................................................27
Vibrations Lab..................................................................................................................28
Thermo Fluids Lab...........................................................................................................30
Safety Document...............................................................................................................32
Bill of Materials...............................................................................................................41
Scope of Supply................................................................................................................42
ANSYS Models
Test CellThe 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 times in the areas of concern to make sure the model was accurately capturing true deformation and stress values. After two iterations both stress and deformation plateau at values shown. Results as followed:
Figure 1: Deformation due to static load of compressor (top view) (MAX = .00402in)
Initial testing of the static load showed that there was a larger then acceptable stress and deflection in the supporting surface. Working with our senior design team’s PE it was recommended that two I-beams be inserted under the final location of the compressor.
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 material was defined as structural steel and imported into ANSYS. The I-beams were constrained as shown above 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 the deflection of the floor decreased dramatically to below one thousandth of an inch. To determine if there could be any improvements by moving the I-beams more centrally towards the highest deflection and stress areas, the ANSYS models were rerun with the beams moving inwardly in steps of one-foot increments. 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
Compressor SkidUsing 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 to ensure the model was accurately capturing true deformation and stress values. It was refined again after three iterations; all plateau values are stated. Results as followed:
Figure 7: Total deformation of skid due to moment created by primary forces (MAX=.0054464 inch)
Figure 8: 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.
Cooling Loop Calculations & SpecificationsSome of the heat of compression is transferred through the cylinder wall into four water jacket channels. Each of these channels are 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.
delta t in compressor 116.6667 KCyl. wall thickness 0.5 inchjacket width 2 inchcircum 21.9911 inchnumber of jackets 2 #K steel 43 W/m*KK water 0.58 W/m*KWater flow 150 GPHDensity of water 999.8395 kg/m^3assumed hydraulic D 1.1284 inMass flow rate 0.1577 kg/sViscosity of water 0.0003 Pa*sCp water 4181.3 KJ/Kg-K
Relevant Parameters
Heat transfer (conduction + convection)
Heating fluid in round channel
Reynolds number equation
Heat transfer coefficient
Results:Re 5560.1048 #prandtl number water 7.0000 #nusselt number 49.6402 #h forced convection 57.5826 BTU/ft^2*hr*F
Q 234.2986 WQ*4 channels 937.1943 3198.6441 W BTU/Hrdelta t of water 8.731621881 oF
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.
Pump: Shurflo Industrial Pump — 198 GPH, 115 Volt, 1/2in., Model# 2088-594-154http://www.northerntool.com/webapp/wcs/stores/servlet/product_6970_200249074_200249074
Heat exchanger:Brazed Flat Plate Heat Exchanger, Model LA14-10 3/4 NPT inch connection - 8 long by 3 1/4 wide by 2 1/4 incheshttp://www.houseneeds.com/shop/HeatingProducts/HydronicHeating/heatexchangers/mischeatexchangers/heatexchangerbuyage.asp
Coolant Tank:5 Gallon Flat Bottom Poly Storage Tank, 22" L x 10" W x 8" Hhttp://www.plastic-mart.com/class.php?item=2465
Heater: Screw Plug Immersion Heater, 400W, 5/8" diameter, 1/2 NPT Model # EMH-060-120Vhttp://www.omega.com/ppt/pptsc.asp?ref=EMH_Heater&Nav=heaf01
Installation/ Test Cell
Needs and Specifications:
Need Specification Units Range
1 TimelineList of end arrival date and schedule on room preparation activities. List n/a
2
Safety is ensured throughout the installation processes.
Injuries due to installation are minimized and none of the parties involved are liable.
number of
injuries 0
3
Ample amount of room space available to operate machine.
Provide expected room layout of the test cell and the final compressor destination. List n/a
4Reduce impact from sound and vibrations.
Consider the effects the machine will have to its surroundings and evaluate efforts that can be taken during installation to minimize. List n/a
5
Accessibility of the machine for maintenance and use in future projects.
Select the proper compressor position within the room that gives ample room to service the machine safely. Binary Yes
6
RIT maintenance capabilities to provide adequate service.
List current capabilities RIT and the senior design teams have for servicing the machine. These include tools, methods of lifting equipment, mechanical and electrical supplies, storage space for parts, and safety equipment. List n/a
7Provide sufficient support for compressor operation.
Account for the weight and other forces exerted by the compressor. lbs
7500-10000
Timeline: Incorporated into Senior Design II Timeline and Installation Procedure
Safety: Use of Rigging Company that has substantial experience moving heavy equipment.
Space: Layout of room with clear path ways around machine for maintenance and operation in Test Cell. Ensured obstructions such as overhead lights, exhaust systems, and doors are not threats.
Vibrations: Vibration dampening is not necessary due to the configuration of the compressor and the building. Current Test Cell has sufficient acoustic capabilities.
Accessibility: Position of compressor was selected to allow for sufficient maintenance space on each side of the machine and room for Auxiliary Unit installation.
Maintenance: Tools will be ordered to service machine as well as proper storage space for parts and materials. Lifting requirements are suitable with current shop supplies for parts that may need to be removed. Electrical and mechanical supplies necessary were verified and are accessible to machine. Proper safety equipment and placement of clearly visible signs have been planned for.
Structural: Analysis of floor was performed to determine effects of static load. Structural consultants have been used to verify analysis. I-beam reinforcement is required.
Installation Procedure:- Formula Team and other projects has vacated room:
o Engine Dyno will be removed from the back 4 feet of the room by beginning of 1st week of fall quarter to allow for housekeeping in room.
o All tools and other supplies not pertaining to compressor will be removedo Need to have clear access to floor and surrounding walls of test cell.
- Senior Design Team will prepare for the compressor’s arrival:o Manage the logistics of the contracted work
Work with general contractor to locate ideal placement of I-beams Install I-beams
Figure 1: Basement view of Test Cell, Reinforcement and Mounting Detail Provided by Structural Engineer
o Order and purchase all items for the installation, interface, and education materials needed
Storage racks Tools Safety Equipment Mounting hardware and plates Sensors DAQ and mounting equipment
o Provide necessary information to Boulter: Schedule and route for transportation. Materials necessary for install. Structural concerns and requirements.
Provide structural engineer’s analysis and suggestions.
Willis BoulterCell Phone: 585-261-3102Boulter Industrial Contractors, Inc.610 Salt RoadWebster, NY 14580Phone: (585) 265-3260Fax: (585) 265-0605E-mail: wboulter@boulter1.com
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.
- Preparations by Boulter for relocation: o Transport machine from Dresser-Rand to Boulter Rigging Company
Provide sufficient time for Boulter to define needs for transportation.
Verify that the correct equipment is used and 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.
Fork lift will place machine on skates in new addition of shop. Use bar stock to find C.O.G and secure firmly.
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.
Figure 2: Building 09 Transport Route
- 45 feet of transportation across floor with basement underneath.- Loading bay area has foundation and can use fork lift up to the entrance to the old
machine shop.- Load of the compressor must be applied over 60ft2 to prevent damaging of structure
Figure 3: Top View of Test Cell with Components and Locations
- After Installationo Coordinate with FMS to manage the logistics for the completion of
contracted work Electrical hookups Ventilation Chilled water loop
o Install and hook up cooling system Coolant tank, heat exchanger, heater, valves and piping
o Assemble and install storage rack 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.
o Place computer, DAQ, tools, spare parts, etc. in proper locationso Provide all safety material in the test cell.
Post signs and stickers Place necessary safety equipment in the room (see safety document)
o Install and hook up sensors and data acquisition unit See sensor document for specifications and locations.
Final List of Sensors
Sensor InstallationThere 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 is manufacturers’ preferred installation methods for the sensors to be used in the DAQ system.
Source: http://www.pcb.com/techsupport/tech_accel.php
Adhesive MountAdhesive 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 MountMagnetic 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 MountingThis 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 MountingLike a stud mount installation, screw mount installations are to be used on thin-walled 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.
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 Interfaceo Turn program ono View Graphs Screen and see if they can easily interpret information on the
screeno Turn program offo Close out Compressor Interfaceo Access excel file
Assessment Factors:o Thought process of subject as they are performing actionso Frequency of help requestso 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.
Vibration Trip-Switch
1) Mount the Vibe Trip-Switch to the Vibration Shaker in 09-2100 “Vibrations Lab”.
2) Use LabVIEW to create a customized adjustment program.
3) Adjust the shaker to the desired vibration levels.
4) Connect a multi-meter to the Vibe Trip-Switch to test for an open or closed circuit.
5) Turn on the Vibration Shaker.
6) As Vibration Shaker escalates, ensure the Vibe Trip-Switch trips at desired vibration
level.
7) Disconnect the apparatus.
Air Flow Results1) 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.
Gravity Inlet1) Open the gravity inlet valve.
2) Close the room doors.
3) Use a barometer to measure the air pressure in the room (baseline).
4) Turn on the exhaust fan.
5) Continue measuring and recording the air pressure every minute for 10 minutes.
6) If the air pressure levels remain constant, then the gravity inlet valve is sufficient.
7) If the air pressure levels decline, then the gravity inlet valve is not supplying enough
air.
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-Stops1) 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 in the back of the room.
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 Checks1) Refer to the official “Maintenance Manual” for important details and tests that should
be conducted during the first time the compressor is run after installation.
2) Record all noticeable areas of moving parts that are potential safety hazards or pinch
points.
3) Record any unexpected noises that occur.
Lock-Out Tag-Out for Compressor1) 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 Levels1) 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 Temperature1) 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).
Vibrations1) 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 Compressor1) 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 Capabilities1) 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.
Vibrations Lab
Investigation: Damping provided by Skid
This investigation looks at how much damping the skid is providing to the singe cylinder
system. ANSYS was used to develop a theoretical model of the skid and the forces applied
to it. 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, 10 in total. The forces due to reciprocation
were then applied to the model at compressor mounting locations. The max deformation
was found to be 0054464 inch.
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 vibration tab and begin logging
accelerometer 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.
Create a formal report section comparing experimental data with theoretical predictions,
following the guidelines and specific topics below.
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.
Thermo Fluids Lab
Investigation: Compressor P-V Diagrams
This investigation explores the concepts of adiabatic 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.
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. The pressure in the cylinder should also be 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.
Safety Document
Observe All Hazard and Warning Labels
PERSONAL PROTECTITIVE EQUIPMENT
Always Wear the Appropriate Safety Gear
Steel toe shoes
Safety glasses or goggles
Gloves
Hard hat
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 SAFETYUse 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
Bill of Materials
Scope of SupplyA scope of supply list was created based off the hazard analysis findings.
With the ability to customize portions of the compressor, the scope of supply will communicate RIT’s specific needs to Dresser Rand.
- Relief Valve repositioned - Kill Switches: Incorporate into control panel
o Kill switch activated by vibrationo Kill switch activated by pressureo Kill switch activated by over heating
- E-stop o Incorporate into control panel
- Bore Holeso Need placemento Characteristicso Number
- Weld Handles to access panels
- Piston access panels made of Lexan
- 5 gallon tank
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