P12452 Vibration Isolation and Novel Cooling System. Final Project Summary May 18, 2012

Transcription

1 P12452 Vibration Isolation and Novel Cooling System Final Project Summary May 18, 2012

2 2 Members Team John Burns Project Manager Ryan Hurley Principle Engineer Chris Guerra Thermo-Fluids Engineer Matt Kasemer Vibrations Engineer Support Bill Nowak Faculty Guide Dr. Jason Kolodziej Primary Customer Scott Delmotte Dresser-Rand Contact James Sorokes Dresser-Rand Contact

3 3 Agenda Project Background Customer Needs Summary Design Summary Results Future Work Lessons Learned Acknowledgements

4 PROJECT BACKGROUND 4

5 5 Reciprocating Compressors Typically used to compress process gas in refineries Traditionally configured as opposing throws to reduce vibration, with hard-mount to large concrete pad. Both forced and thermosyphoning systems used for cooling.

6 6 RIT Reciprocating Compressor Smallest reciprocating compressor Dresser- Rand manufactures Bore 6 inches Stroke 5 inches Operating Pressure ~45psia 360 cycles per minute (6 Hz)

7 7 P12452 Project Scope Understand operating conditions of the compressor End Goals Design, evaluate, install and test a vibration isolation system. Design, evaluate, implement and analyze a thermosyphoning system.

8 8 Customer Needs Summary Primary customer needs to address: Vibration Isolation: ~50% vibration reduction System should be removable Novel Cooling: Keeps compressor at safe operating temperature Transition from thermosyphoning to pump-driven system should be as simple as possible

9 DESIGN SUMMARY 9

10 10 Vibration Isolation Solution Parallel design paths: Magnetorheological (MR) Dampers (LORD Corp.) Infinite adjustability, educational value, donated Standard automotive shocks (Monroe) Low cost, no outside power requirements, readily available Brainstorming Initial Design Final Install

11 11 Thermosyphoning System No use of outside power Cooling amount is self adjusting Initial Design Final Install

12 Thermosyphoning VI 12

13 13 Project Budget **Misc. Expenses include tools, mileage & food reimbursements, etc.

14 RESULTS SUMMARY 14

15 15 Vibration Isolation Results Some issues were encountered with the automotive dampers The automotive dampers proved to be ineffective in damping any of the vibrations present in the system. The was not a huge issue, because they were originally designed as a failsafe backup to the MR damper design. The original design of the MR damper mounting system proved to be inadequate, with an unforeseen tolerance stackup and design flaw adversely impacting performance. Red Arrows: Tolerance Stackups Green Arrows: Bending

16 Vibration Isolation Results- Cont d 16

17 Vibration Amplitude 17 Vibration Isolation Results- Cont d 1.50 Normalized Vibration Data MR Dampers with Tolerance Stackups Time Free System MR Dampers with Refined Manufacturing Processes

18 Temperature (C) 18 Thermosyphoning Results Discharge Air Temperature Comparison Discharge Air Very High Discharge Air Very High - TS Discharge Air High Discharge Air High - TS Compressor turned off at ~6300s to test flow meter Time (s)

19 Temperature (C) 19 Thermosyphoning Results Comparison of Forced Cooling v. Thermosyphoning Cooling Coolant Out Head Coolant Out - Head - TS Coolant Out Mid Coolant Out - Mid - TS Coolant Out Crank Coolant Out - Crank - TS Coolant In After Finned Tubing - TS Coolant Out All Before Finned Tubing - TS Compressor turned off at ~6300s to test flow meter Time (s)

20 20 Future Work Investigate and reduce vibration transmission to floor Different finned tubing arrangements Flow issue through thermosyphoning system Research opportunities

21 21 Lessons Learned Machining always takes longer than you predict! Leave time for redesigns Shop managers are lifesavers Designs needs to be validated again after ANY design changes. Evaluate every assumption and is repercussions thoroughly Thermosyphoning is still magic

22 22 Acknowledgments LORD Corporation Bill Nowak Dr. Jason Kolodziej Scott Delmotte Promit Bagchi P12453: Cody Anderson Robin Leili-Marrazzo Markus Holzenkamp Dr. Stephen Boedo Dr. Marca Lam Dr. Mark Kempski Dr. Amitabha Ghosh Dave Hathaway Rob Kraynik Steve Kosciol

23 Questions? 23