Reciprocating Compressor Installation and Validation

Transcription

1 Reciprocating Compressor Installation and Validation MSD II John Blamer (ME) Team Leader Promit Bagchi (ME) Lead Engineer Elliot Kendall (ME) Hydronics Engineer Matthias Purvis (ME) Operations Engineer

2 » Agenda Background Project scope Deliverables Installation Current State of Design Delivery Mounting Coolant System Compressor Sheave/Internal Components DAQ Conclusion Recommended Future Tasks Permanent DAQ Solution Thermodynamics Lab Vibrations Lab Questions

3 » Background Continuation of SD group P09452 Reciprocating compressor donated to RIT by Dresser-Rand Installed in ME Machine Shop For research and educational purposes P09452 did significant preparation work Shipped from D-R facility in India Should have arrived in Port of New York on October 25 th Trucked to Boulter Rigging Delivered and installed at RIT December, 17th

4 » Project Scope Understand compressor Basic operation Hardware Understand installation needs Vibration isolation Cooling system Electrical and DAQ After install, focus on education and Beginning of Life characterization

5 » Deliverables Compressor installed and operational by end of Implement a preliminary DAQ system Measure/document beginning of life data from the compressor Review, test, and validate the Thermodynamics and Vibration labs created by P09452

6 » Installation Installation Issues Original compressor location would interfere with large concrete beam 12 x14 concrete beam directly under bolting locations Moved unit 12 in Y-direction to avoid beams X location maintained to remain within support of I-Beams Two bolt holes would interfere with I-Beam Concrete anchors to be used in those locations Better position Control panel door clearance Ample space around unit Concrete Beam Original Location Concrete Beam I-Beams View from Basement Y X

7 » Installation Delivery Issues 1.) Compressor would not fit through test cell door frame 2.) Compressor is 3 wider than expected (control panel) 3.) Possible Solutions: Bring compressor in at an angle Remove door frame Cut-off control panel and relocate 4 in-board towards compressor 4.) Selected: Cut-off control panel and relocate 4 back towards compressor 5.) Confirm idea with Dresser-Rand Instruct Boulter on modification on the morning of delivery 6.) Successfully fit compressor into test cell

8 » Installation - Mounting Unit can create significant vibrations Vibrations must not be transmitted to building 10 vibration-isolating mounts donated by LORD Corp.

9 » Installation - Mounting Adapter plates fabricated to attach mounts to frame Mounting holes drilled in compressor frame Mounts bolted through concrete floor Hammer drilling caused damage to floor 7 bolts through floor, concrete anchors for remainder Repaired with SpeedCrete PM Concrete Repair 6 x6 steel plates under floor Plans approved by Jason Vigil Jensen Engineering

10 » Installation Coolant System Supply cooling water to compressor 4-6 gal/min 80 F water to prevent condensation psi pressure Thermostatic mixing valve Water reservoir Water pump Heat exchanger Pressure Section Drop (psi) Head loss (ft) (Piping) (Compressor) (Piping) (HX) (Piping) (Tank) (Piping) (Pump)

11 » Installation Original Cooling System Original system donated by Professor John Wellin 50 gal reservoir 1/3 hp pump (Insufficient flow) Heater w/ circulating pump Flow-meter Upgraded motor turned out to be insufficient Pulling excessive amperage Overheating Original System

12 » Installation Coolant System Head (feet) Dayton 1/3 HP Multi-Stage Booster Pump Curve Replaced pump with Multi-Stage Dayton Pump 1/3 hp, 8-stage Modified frame to accommodate new pump Pump operating in optimal range Added pressure gauge Flow (gpm) Final System

13 » Installation Compressor Sheave/Internal Components Attach ~150lb compressor sheave (pulley) Position balance weight in correct location Alignment of compressor and motor sheaves Attach Belts Tighten belts to specified load Install scraper rings Install packing rings

14 » DAQ Stud mounted accelerometers (X,Y, Z) Signal conditioners USB DAQ device with 8 analog inputs X-Axis Accelerometer Y-Axis Accelerometer Z-Axis Accelerometer Signal Conditioner Signal Conditioner Signal Conditioner Flow chart of current DAQ system National Instruments USB DAQ System Laptop Signal Conditioners Y Z X USB DAQ Enclosure Accelerometers

15 » DAQ Acceleration [m/s 2 ] 6 Compressor Oscillatory Response Time [sec] X Z Y Amplitude vs. Time X Y Z Amplitude (m/s 2 ) Frequency (Hz) Primary vibration occurs at 6hz (360rpm) Correlates to piston motion Smaller vibration signature at 12hz Amplitude vs. Frequency

16 » Conclusions Completed: Installed compressor and prepared it for testing Vibration isolation, and cooling system DAQ system, accelerometers, and characterized vibrations data Incomplete: Acquire all of the recommended sensors Completely characterize compressor performance Test and revise thermodynamics and vibrations labs Could have accomplished more by: Utilizing better risk management Purchasing all necessary components earlier

17 » Recommended Future Tasks Permanent DAQ Solution Fully understand pros and cons of current USB DAQ system Invite personnel from National Instruments to come to RIT For advice on which system would be best for research and educational needs. Work closely with Dresser-Rand to see what DAQ systems they use Dr. Kolodziej would like a similar set-up as DR Needs to fit within our allotted budget

18 » Recommended Future Tasks Thermodynamics Lab Review and revise Thermodynamics Lab previously created by P09452 Test lab with current Thermodynamics students and/or professors Lab needs to be error free, easy to follow and achievable Acquire necessary sensors Recommendations: 2 pressure sensors to be placed in the existing fittings located on the piston cylinder (See picture) Encoder to measure crankshaft rotational speed

19 » Recommended Future Tasks Vibrations Lab Create new Vibrations Lab Possibly including: Comparison of theoretical and actual vibration transmissibility Using LabView, make a Acceleration vs. Time graph Graph Frequency Response Install shock absorber, measure change in deflection Thoroughly test lab Needs to be error free, easy to follow and achievable.

20 » Recommended Future Tasks Hardware Construct new cooling system frame Steel construction rather than wood Smaller reservoir More compact design Implement a damping system to reduce compressor oscillation Utilize adjacent room for Control Room Correct power-on switch on control panel Collect vibration data in various locations on the compressor frame Incorporate filter or bypass valve for sediment in cooling system

21 » Lessons Learned Always double check critical calculations No detail is too insignificant to overlook Seek professional guidance in unfamiliar situations Always verify the accuracy of background information and existing project documentation Expect delivery delays Don t expect systems to interface immediately Cost should be a secondary concern to functionality

22 Special thanks to: Dr. Kolodziej Bill Nowak Scott Delmotte Dresser-Rand Corp. LORD Corp. Dave Hathaway and ME Machine Shop Staff John Wellin