MSD 1 P12453 Detailed Design Review Markus Holzenkamp Robin Leili Cody Anderson 5/17/2015 Detailed Design Review 1

Agenda Introduction (1 min) Project Background (2 min) Customer Needs (2 min) Revised Engineering Specs (5 min) Risk Management (5 min) RITDAQ (40 min) – Analog – Thermocouples Bill of Materials (10 min) – Complete – Cost Overview LabView VI Interface (10 min) Test Plan (10 min) Questions 5/17/2015 Detailed Design Review 2

Team Members TEAM: Project Manager: Markus Holzenkamp (ME) Project Engineers: Cody Anderson (ME) Robin Leili-Marrazzo (ME) CUSTOMER: Dr. Jason Kolodziej, ME Department, RIT Dr. Edward Hensel, ME Department, RIT SUPPORT: Project Guide:Bill Nowak (Xerox) Faculty Champion:Dr. Kolodziej (RIT) Sponsors:Scott Delmotte (D-R) James Sorokes (D-R) Britt Dinsdale (D-R) 5/17/2015 Detailed Design Review 3

Customer Needs PriorityNeed 1Learn RITDAQ capabilities and propose and implement improvements in code to generate p-v diagrams, time and frequency plots 1Propose and install possible additional sensors to measure stage pressures, stage temperature, bearing temperature 2Install Envision System 3Select, install, and integrate encoder 99Develop future undergrad/grad labs 5/17/2015 Detailed Design Review 4

Project Scope Understand the current state of the compressor – Current sensors, DAQ capabilities – Operation characteristics of reciprocating compressors Install and run ENVISION Condition monitoring system to be donated by Dresser-Rand Increase the current DAQ capabilities End Goal: Design, develop, and install effective health monitoring capabilities 5/17/2015 Detailed Design Review 5

Sample Engineering Specs (Updated) Specification Unit of Measure Margin al Value Ideal Value Actual Value Encoder Resolution pulses per rev (x4) crankshaft / encodershaft ratio 1011 Encoder Lifetimecycles TBD Voltage required by sensorsV Sensor Cost$10000<300 Sensor OutputV 0-5 Sample Rate of the RITDAQHz 0<370kHz TBD Total number of analog sensors#0<1613 Total number of thermocouples#0<1612 Pipe thread size ½”- ¾” NPT 1/8” – ¾” NPT 5/17/2015 Detailed Design Review 6

Concept Selection 5/17/2015 Detailed Design Review 7 Concept Selection (week 3) Concept Selection (week 7) Concept Sketch (week 8)

Risk Assessment 5/17/2015 Detailed Design Review 8

Risk Assessment 5/17/2015 Detailed Design Review 9

RITDAQ Channel layout and sensor attachments 5/17/2015 Detailed Design Review 10

DAQ Channel Layout (Analog) 5/17/2015 Detailed Design Review 11

DAQ Channel Layout (Analog) 5/17/2015 Detailed Design Review 12

Flow meter How? Insert in flex-hose section Why? Easy to modify layout Cost efficient Materials Needed: -hose clamps (x2) -Adapter (x2) 5/17/2015 Detailed Design Review 13

Tank Pressure 5/17/2015 Detailed Design Review 14

Tank Pressure How? Use Rosemount Alphaline 1151 Mounted on compressor base Connected with pressure tubing Why? Already have sensor Easy to place T-Piece before analog gage Materials Needed: -T-Piece -Adapter -Thermocouple fitting 5/17/2015 Detailed Design Review 15

dP across orifice tank How? Use Rosemount sensor Mount in basement with tank Why? No room constraints Out of the way Materials Needed: -Hardware -Adapter (x2) -Elbow 5/17/2015 Detailed Design Review 16

Photocraft HS20 Encoder How? Use included mounting bracket to attach to oil pump housing Why? No modifications to existing structure Materials needed: - 7/16-14 Bolt 3in long - 7/16-14 nuts 5/17/2015 Detailed Design Review 17

DAQ Channel Layout (Thermocouples) 5/17/2015 Detailed Design Review 18

DAQ Channel Layout (Thermocouples) 5/17/2015 Detailed Design Review 19

Inlet Coolant Temperature How? Attach T-Piece between flex hose and steel flange Why? No modifications to existing structure Inlet coolant is at room temperature, heat loss is negligible along steel pipe Materials Needed: -T-Piece -Hose Clamp -Adapter for Thermocouple -Thermocouple fitting 5/17/2015 Detailed Design Review 20

Cylinder Coolant Layout 5/17/2015 Detailed Design Review 21

Head Outlet Coolant Temperature 5/17/2015 Detailed Design Review 22

Head Outlet Coolant Temperature How? Attach fitting to plugged hole and insert thermocouple directed at top outlet Why? No modification of existing structure Measures right at the outlet Materials Needed: -Thermocouple fitting -Adapter 5/17/2015 Detailed Design Review 23

Center Outlet Coolant Temperature How? Attach fitting with thermocouple to plugged hole adjacent to outlet Why? No modification to existing structure No losses Materials Needed: -Adapter -Thermocouple fitting 5/17/2015 Detailed Design Review 24

Tail Coolant Out Temperature 5/17/2015 Detailed Design Review 25

Tail Outlet Coolant Temperature How? Drill and tap hole in pipe. (4mm wall thickness) Why? Close to outlet No mixing with other coolant flows Materials Needed: - Thermocouple fitting 5/17/2015 Detailed Design Review 26

Tail Coolant Out Temperature Test strength of threading schedule 80 pipe. 5/17/2015 Detailed Design Review 27

Combined Outlet Coolant Temperature How? Drill and tap hole in bottom of flow sight Why? Close after all 3 coolant outlets combine Sufficient wall thickness to secure enough threads for fitting Materials Needed: - Fitting for Thermocouple 5/17/2015 Detailed Design Review 28

Combined Outlet Coolant Temperature 5/17/2015 Detailed Design Review 29 Measuring the temperature of the cooling pipes at various locations

Coolant Temperature Before and After Chiller How? Insert T-Piece between flex hose and Chiller inlet Why? Easy to add piping at this place Materials Needed: -T-Piece (x2) -Adapter (x2) -Thermocouple fitting (x2) 5/17/2015 Detailed Design Review 30

Crankcase Oil Temperature How? Attach fitting with thermocouple in plugged hole in crankcase Why? No modification of existing structure Materials Needed: -Adapter -Thermocouple fitting 5/17/2015 Detailed Design Review 31

Crankshaft Bearing Temperature 5/17/2015 Detailed Design Review 32

Crankshaft Bearing Temperature How? Drill into crankcase until just before bearing journal Insert thermocouple to measure temperature of crankcase at that point Assistance from Dresser-Rand Why? Does not alter bearing function Will show trends of bearing temperature accurately Materials Needed: - Thermocouple fitting (x2) 5/17/2015 Detailed Design Review 33

Bill of Materials 5/17/2015 Detailed Design Review 34

Cost Breakdown BUDGET$3000 Sensors$1089 Wiring$88 Hardware$243 TOTAL COST$1420 5/17/2015 Detailed Design Review 35

LabView Interface Goals: Clearly display compressor data Time domain and Frequency domain P-v diagram for forward stroke and backstroke 5/17/2015 Detailed Design Review 36

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PRELIMINARY TEST PLANS 5/17/2015 Detailed Design Review 38

Sensor Tests Means of testing sensor functionality SigLab Existing USB DAQ RIT DAQ 5/17/2015 Detailed Design Review 39

RIT DAQ Cross referencing sensor outputs with existing DAQs and Signal Analyzers Use USB DAQ to validate signals Use SigLab to validate signals Reference expected values to ensure proper sensor readings 5/17/2015 Detailed Design Review 40

Envision System Utilize the functionality of the RIT DAQ Use the functioning RIT DAQ to ensure the Envision System is displaying proper outputs RIT DAQ will already be cross referenced with alternative Signal Processors and validated 5/17/2015 Detailed Design Review 41

Preliminary MSD II Schedule 5/17/2015 Detailed Design Review 42

Questions? 5/17/2015 Detailed Design Review 43