1. EDGE™ Concept Level Project Plan P08452 – Fault Detection and Diagnosis in Rotating Equipment for the Energy Industry Garry Studley (Mechanical Engineering)

2. EDGE™ Concept Level Project Plan Project Name –Fault Detection and Diagnosis in Rotating Equipment for the Energy Industry Project Number –P08452 Project Family –Sustainable Technologies for the Global Marketplace Track –Sustainable Design and Product Development Start Term –2007-2 planned academic quarter for MSD1 End Term –2007-3 planned academic quarter for MSD2 Faculty Guide –Dr. Margaret Bailey (Mechanical Engineering) This is confirmed. Faculty Consultant –Dr. Elizabeth DeBartolo (Mechanical Engineering) My choice because I am taking a class with her that teaches nondestructive inspection techniques. Faculty Consultant –Dr. Mark Kempski (Mechanical Engineering) I chose Dr. Kempski due to the need for integration into Dresser-Rand’s Control Systems and the Vibration aspect. Primary Customer –Scott Delmotte, Dresser-Rand Company – This is confirmed (Possibly working with Joe Tezca).

3. EDGE™ Phase 0: Planning Mission Statement Product Description Design and build a health monitoring system for some piece of turbo machinery (most likely a compressor). The system would collected data through monitoring of key parameters under normal and failure operation. Common sources of failure will be collected from customer knowledge and compiled into a database for future use. The User Interface will be simple to use and allow for proper communication of clearly formatted data that can be compiled into a database. The project will look at producing guidelines and documentation on operation for future use by the customer and RIT. Key Business Goals –Identify problems in operations of machines so a solution or a replacement can be issued before impending failure occurs. This would save on shutdown time and any other unneeded failures or expenses. –Dresser-Rand hopes to open a new market to its business by testing the feasibility and effectiveness of the system. This would hopefully strengthen existing client relationships. –The project could provide for greater efficiencies of turbo machinery without undesired shutdown time due to failure ($$$). Primary Market The Primary Market is Dresser-Rand Co. –Product would be used in support of the operation of turbo machinery. –Future plans could include mass implementation on the turbo machinery industry (oil, power generation, etc). –Could offer replacement parts/services sooner on all machines in the industry. Secondary Market Oil Pumping Companies, Power Plants, Pipeline (Natural Gas) –Regardless of the brand of turbo machinery equipment used. –May want to monitor own machines to prevent any shutdowns/failures or to gain knowledge on which parts to replace during future scheduled shutdowns. –Also would give an idea that maximum production was being achieved. Stakeholders End Users: Dresser-Rand Company, Power Plants, and Major Oil Companies Developer: RIT (could possibly lead to a Future Fault Detection Lab, use in Master’s Thesis Project) Society: Environment (efficiency) and Oil Production Original Equipment Manufacturer: Dresser Rand Company, etc. Machine Operators: In the field/testing at Dresser-Rand Machine Inspectors/Field Service Representatives/Assembly Men: Hired by Dresser-Rand/Oil Companies

4. EDGE™ Overview of Reciprocating Compressors

5. EDGE™ Overview of Turbo-machinery

6. EDGE™ Phase 1: Concept Development Identify Customer Needs - Interviews Primary Customer(s) Dresser-Rand Personnel Interviewed: –Scott Delmotte (Primary Contact for Reciprocating Compressor Knowledge) –Joe Tecza and Jay Koch (Centrifugal Compressor Knowledge and acquiring the piece of equipment for the project) Other Stakeholder(s) RIT –Faculty guide, Margaret Bailey about her definition of the project and possible means to complete. –Dave Hathaway about the observation cell this equipment will be placed in and the effects on RIT. Past Senior Design Team(s) I have not seen any other past senior design projects that were done in the same industry as this project. Dr. Margaret Bailey has participated in projects that concerned health monitoring systems on Vapor Compression Refrigeration (VCR) cycle plants. The types of performance issues identified and used in that project might be implemented here. Also, the type of library/sensors developed in that project might be able to be copied in this application.

7. EDGE™ Phase 1: Concept Development Identify Customer Needs - Benchmarking Competitive or Cooperative Solutions –Benchmark 1: Bently-Nevada System 1 - Optimization and Diagnostics Software –System 1System 1 –Bently-NevadaBently-Nevada –Provides software and hardware for product optimization, condition monitoring, and event diagnositcs. This is done through integration of all systems into one display with a strong centralized database. System 1 is applicable to a wide range of products and equipment including compressors, turbines, and electrical devices. The type of faults detected are related to thermo/fluids and vibrations with the ability to give warnings and trend data. –Benchmark 2: Prognost Condition Monitoring –Prognost Condition MonitoringPrognost Condition Monitoring –PROGNOST Systems GmbHPROGNOST Systems GmbH –On-line condition monitoring of reciprocating compressors and pumps. Allows for improved safety, machine availability, and efficiency. Improves decision making in terms of repair and replacements by providing knowledge on the operation characteristics of the machine. Has the ability to monitor, analyze, and interpret high frequency data to help determine machine reliability. Helps maintain critical economic efficiency of reciprocating compressors. Benchmark 3: Windrock Incorporated –Windrock Inc.Windrock Inc. –Provides on-line performance monitoring for reciprocating engines, compressors, and centrifugal products. Measure mechanical condition and unit performance as well as parameters of horsepower, flow balance, temperature, ultrasonic, and vibration. Incorporates the use of software, hardware (sensors), and systems. Allows the user to monitor, trend, alarm, and diagnose compressor condition and performance

8. EDGE™ Phase 1: Concept Development Identify Customer Needs - Interpret Needs Statements: The main objective of the project is to develop a method for data acquisition of key parameters from an air compressor that can be used in the future for comparison of performance characteristics. The solution for the project should be generic for implementation onto multiple Dresser-Rand products. The control systems and signal processing methods should integrate in current Dresser-Rand systems as much as possible. Provide a user interface for operation and interpretation of data acquisition. Fault data needs to be collected with clearly documented procedures. The system should provide data on faults that generate thermo/fluids and vibrational responses.

9. EDGE™ Phase 1: Concept Development Identify Customer Needs - Interpret Organize the Needs into a Hierarchy –Need 1: Data Acquisition Need 1.1: Multiple Parameters Need 1.2: Wide Ranges of Data –Need 1.2a: Applied to Different Products –Need 1.2b: Application to Other Product Lines Need 1.3: Compiled into Usable Format –Need 1.3a: Limited Noise –Need 1.3b: Accuracy Need 1.4: Ability to Collect Failure Data Need 2: Integration to Dresser-Rand Need 2.1: Products and Product Lines –Need 2.1a: Inlet and Outlet Conditions –Need 2.1b: Faults Need 2.2: Control Systems –Need 2.2a: Signal Processing –Need 2.2b: Compiled Data Need 2.3: Failures of Interest –Need 3: Operation of System Need 3.1: Remotely –Need 3.1a: Start Up –Need 3.1b: User Interface Need 3.2: User Friendly –Need 3.2a: Ease of Use –Need 3.2b: Ergonomics Need 3.3: Data Interpretation –Need 3.3a: Straightforward –Need 3.3b: Cleary Compiled Need 4: Inducing Faults Need 4.1: Common Faults that are critical to Dresser-Rand –Need 4.1a: Responses –Need 4.1b: Data Signatures (Possible Customer Library) Need 4.2: Guidelines –Need 4.2a: Clearly Written –Need 4.2b: Repeatbable

10. EDGE™ Phase 1: Concept Development Identify Customer Needs - Interpret

11. EDGE™ Phase 1: Concept Development Health Monitoring System Constraints Lead Times on the Equipment needed $$$ Availability of spare parts and ability to install these parts Vagueness of Sensor Data Proper Identification of Faults with their causes Complexity of Fault Identification Neural Networks Facility to Operate a piece of turbo- machinery Resources People Dresser-Rand RIT Faculty Vendors Equipment Machine with proper inlet/exhaust conditions Electrical Power Computer Resources Purchased Items (ex: Sensors) Time Economics Budget of $8000 Donation of Machine and necessary spare parts to induce faults Discounts & Donations on Purchased Items Means to Operate Machine (Electric, Supplies, etc) Trips to Dresser-Rand Facilities Scope Customer Library Robust Identifies Faults and their locations Data Acquisition Induce Faults Sensor Selection and Placement Power Supply Remote Access and Operation Technology Control Systems Integration Application to multiple product lines Generalized Solution Machine/System Capabilities Sensors Control System Website Updates Market Ready

12. EDGE™ Phase 1: Concept Development Identify Customer Needs - Interpret

13. EDGE™ Phase 1: Concept Development Establish Target Specifications

14. EDGE™ Phase 1: Concept Development Establish Target Specifications

15. EDGE™ Phase 0: Planning Staffing Requirements Mechanical Engineers 3 –Responsible for learning and determining what causes of failure are most prominent and the biggest cause of lost money/time. –Determine possible indicators that could be used to trigger a response from the health monitoring system. –Thermodynamics, Fluid Mechanics (Transport), Vibrations, Control Systems, Labview, etc. –I have not spoken with any mechanical engineers but would have the best means to recruit students in this field. Electrical Engineers 1 –Help develop the integration of the project between the mechanical component and the health monitoring system. –Electrical components (sensors), Data Acquisition (Labview or other coding), Power –Circuitry Design, Power Implementation, Coding of the System, etc. (to develop the sensors that might be used on the system). –I have had no contact with any electrical engineers. Industrial and Systems Engineers 1 –Compile and implement the failure/fault data into the health monitoring system. – Documentation, Help with Management, Coordination of Time, Money, Resources (Equipment and Labs), and any Trips. –I have had no contact with any Industrial Engineers. Computer Engineers 1 –Assist Electrical Engineer activities on any programming that may need to be done on the health monitoring system. –Work with Labview, Data Acquisition, Integration of Control Systems, and Possible Development of Neural Networks –No Contact Business Majors 0 –Help develop a business plan for the product which is new in this field. –Background in technology management and innovation (developing new products for existing markets). –No contact

16. EDGE™ Phase 0: Planning Staffing Requirements Garry Studley - Project Manager Main task is to be the team lead and project manager, which includes decision making, assigning/monitoring completion of tasks, organizing information, etc. Besides task of managing the team, any issues related with Control Systems will be need to be addressed. Will have contact with the Dresser-Rand team and help build the customer library through interaction with the customer. Also, some overview regarding other main issues involved in the project will need to be covered. This individual should be informal about the scope and direction of the project. TBD Student - ME Main task of this individual is to be the source for all issues relating vibrations, fatigue, and any mechanical aspects of the machine. Will be in contact with Dresser-Rand Rotordyanmic team members in order to build robust library data surrounding this particular issue and its affects on the machine. Should help with the data acquisition (selection of tools) and the interface to the customer. Includes setting up plans to induce faults to collect the necessary data. Might include post processing of the data. TBD Student - ME This individual should be the main source for all concerns regaring thermodynamics and fluids aspects of the machine and data acquisition. Will be in contact with Dresser-Rand Thermodynamic team members to help build customer library to identify faults that should be viewed. Help with the data acquisition (selection of the tools) and the interface to the customer will also be required. This includes setting up plans to induce faults to collect the necessary data. Might include post processing of the data.

17. EDGE™ TBD Student-EE Will have a strong focus in electronics, the embedded systems function, and power management to all the electrical systems. Should be familiar with and strong in Sensor Selection and Interfacing or other data acquisition methods. Majority of their tasks will involve the design, testing, and the compiling of data into usable format. This includes development of filters and signal processing methods that provides a clear signal and communication to the user interface. Knowledge of PCB Layout, Analog and Digital Design, Noise Reduction Methods, and Data Acquisition Techniques will be the bulk of their workload. TBD Student - CE The primary purpose of this individual will be in the development of the Software and Firmware that supports the Data Acquisition (Interface). Focus will be needed in Object Oriented Programming (C, C++, PHP, Labview) that will allow proper data collection and manipulation into a usable format for performance evaluation. Will develop a user interface that is easy to use for application in possible future commercialization. Integration into current Dresser-Rand control systems and development of algorithms will be necessary. Might also provide software for a data signature database (customer library) that will be used for identification of performance status. TBD Student - IE Will provide support in the integration of the fault detection system to Dresser-Rand that specifically includes the usability of the interface. This individual will also help with project management coordination, cost analysis and any decision making concerning the budget. Another major role will involve design of experiments for safely inducing faults consistently. These fault inducing techniques should be documented into a protocol. Should assist the other functions in their tasks as well as ensuring proper communication between individuals. Will make certain that documentation is done throughout Senior Design I & II and play a major role in the completion of all deliverables.

18. EDGE™ Phase 0: Planning Preliminary Work Breakdown Structure PersonWeek 0->1 (7 Dec 07)Week 1->2 (14 Dec 07)Week 2->3+ (21 Dec 07) ME Student1 Research DR Website, Talk with Contacts, Learn about Compressor used, Need for this system, Become Familiar with Lab Setup, Gain any access that needs to be granted Trip to DR facility, Identify targeted sources for customer library, Contact Control Systems Group, Labview training, Sensor Research, Benchmark some current solutions (general) Labview training, Sensor Research, Gain information on typical faults, Learn about integrating into DR control system (generic), investigate non-typical variable readings and sensors used, application of system to machine given and how applied to all products lines at DR ME Student2 Research DR Website, Talk with Contacts, Learn about Compressor used and its operation, Need for this system, Become Familiar with Lab Setup, Gain any access that needs to be granted Trip to DR facility, Identify targeted sources for customer library, Contact Vibrations/Rotordynamics Group, Benchmark solutions that relate to the Vibrations/ Rotordynamic aspect Labview training, Sensor Research, Gain information on typical faults related to Vibrations, Learn about application of Rotordynamics at DR, Investigate possibility of acousitc monitoring, Pressure Wave Forms, application of system to machine given and how applied to all products lines at DR ME Student3 Research DR Website, Talk with Contacts, Learn about Compressor used and its operation, Need for this system, Become Familiar with Lab Setup, Gain any access that needs to be granted Trip to DR facility, Identify targeted sources for customer library, Contact Thermo/Fluids Group, Benchmark existing solutions that relate to Thermo/Fluid Variables Labview training, Sensor Research, Gain information on typical faults related to Thermo Fluids, Learn about differences in products at DR and think of how to bridge gap, learn how to plot P-V plot from data collected, application of system to machine given and how applied to all products lines at DR IE Student1 Research DR Website, Coordinate Week 2 trip, Learn about Testing Procedures at DR, Learn about operation of machine, Become Familiar with Lab Setup, Gain any access that needs to be granted Trip to DR facility, Identify targeted sources for customer library, Manage Contacts that will be used, Document trip and information provided by contacts, Update Website Document and Compile Information other team members are being given by DR Contacts, Continue learning and write up standard on how to operate machine at RIT (base off DR specs), Begin basic setup of standards on Inducing Faults EE Student1 Research DR Website, Talk with Contacts, Become Familiar with Electrical Specs on the machine and its operation, Control System on machine, Become Familiar with Lab Setup, Gain any access that needs to be granted Trip to DR facility, Research Specs on machine and requirements, start sensor research and selection, Labview training and data acquisition, Benchmark existing data acquisition of similar systems and of DR Continue Sensor Selection and Benchmarking to come up with most efficient solution, Compile lists of electrical equipment needed to run the power and sensor information back to the system, Learn more about Labview and how data is recorded. CE Student1 Research DR Website, Talk with Contacts, Become Familiar with Electrical Specs on machne and its operation, Control System on machine, Become Familiar with Lab Setup, Gain any access that needs to be granted Trip to DR facility, Contact Control Systems Group, Learn about programming to be used on project, Labview training and data acquisition, Benchmark existing data acquistion and programming used Continue Sensor Selection and Benchmarking to come up with most efficient solution, Learn about Programming used and setup to access the machine/data acquisition remotely (should be based off DR capabilities in the field), Learn more about Labview and how data is recorded.

19. EDGE™ Phase 0: Planning Intellectual Property Considerations Public This Information would include any designs, documents, etc that rights have been relinquished on. This could include information on the team experiences, benchmarking concepts, resources that have been used or will be used, etc. Probably will contain information of all items presented during the required deliverables. Private A lot of the work and information that is gained from Dresser-Rand contacts will be confidential as is their policy. The information related to explicit details about the customer library is very unique to Dresser- Rand. Also, the sensors and application of the system, data acquisition, etc will be confidential.

20. EDGE™ Phase 0: Planning Team Values and Norms Participation Each member of the team is expected to give full participation and attention while at team meetings. If a member can not make a team meeting, they should inform the other members as soon as they know about the conflict. Information from this meeting should be acquired from the other members or off the team website as soon as possible. Team members are expected to come to meetings on- time, prepared, homework done, and not lag behind regardless if the last meeting was missed. Cooperative The team members are just that, on a team that is working together to achieve the same final end goal. Information should be readily given to help other team members in completing their tasks if needed. Group efforts will be needed at compiling the information and preparing the deliverables. Help should still be offered on topics that a member might not be responsible for. If conflicts do arise, they need to be addressed so progress is not impeded. Preparation Members should be able to provide the information asked of them and complete tasks. Each member might have to and be willing to do the research necessary that would fill any gaps they might have on a particular topic. Any information that might be needed should also be gained from Professors in that area and relayed to the team. Professional Team members should be polite and courteous to the contacts at Dresser-Rand. Schedules will probably conflict and the team member should accommodate the contact. Information given by the contact should be taken with knowledge of its potential confidential nature. This should be respected and credit should be given to the individual. Respect all tasks and requests that the contact may ask.

21. EDGE™ Phase 0: Planning Grading and Assessment Scheme Grade LevelMSD I C All requirements for receiving a "D" plus additional contact at the end of SDI with Dresser-Rand contacts to begin the initial personalization of the Data Acquisition system. The design allows parameters that will be measured to be of some interest to Dresser-Rand but are capable of slight extension past the operating limits of the donation compressor. The user interface design is basic and allows for collection of one trial run at a time with the format of the data still unknown. Required equipment has been briefly considered with some equipment ready to purchase at the end of SDI. B Must fulfill all requirements for "C" and the design allows for the system to be able to measure most parameters of interest to Dresser-Rand at the inlet and outlet. The design ensures that the parameter ranges will cover ranges outside the donation compressor operation limits and covers the ranges for Dresser-Rand's primary reciprocating compressor product. A clear idea of a user interface has been developed that allows for collection of multiple data collection trials. The system has been design with some consideration into integration to Dresser-Rand Control Systems. Guidelines to collect failure data have been considered with completion set for SDII. Contact throughout the quarter was made with Dresser-Rand and equipment needed can all be ordered in the first couple weeks of SDII. A All requirements for a "B" plus a clear personalization and design of a data acquisition system that would address many Dresser-Rand concerns. The design includes meaasuring multiple parameters at the inlet and outlet in broad ranges. The equipment considered has the ability to measure these ranges and is ready to order at the end of SDI. The user interface design includes formating the data, creation of a database, and communication to the user. The team has considered how failure data will be collected and provide guidelines (and needed "bad" parts) to complete this task. The system strongly considered integration into Dresser-Rand methods and a strong contact was kept through SDI. The team has a design to implement and most equipment ordered for SDII with clear documentation of designs/decision making process.

22. EDGE™ Phase 0: Planning Grading and Assessment Scheme Grade Level MSD II C All requirements for receiving a "D" plus initial implementation onto the machine. Some data is collected in a difficult format to understand. The normal operation of the compressor was considered. Training is need on the user interface but allows for collection of data over one trial. Start up of the system is done in person through hands on application. Power is supplied to all components and communication exists between the mechanical and electrical equipment. The system allows for modification in the future. B All requirements for a "C" and addresses Dresser-Rand interests in relation to the data that is collected. The system measures parameters at the inlet and outlet and are capable of being kept within the user interface. The data acquisition equipment is capable of measuring ranges of data outside of the limits held to in SD (clear extension to Dresser-Rand Products). Failure data is capable of being collected under the guidelines developed. The user interface has the means to be used easily with possible development of a database. Communication with and extension to Dresser-Rand has been maintain and shown in the final design. Transition to future projects is very feasible. A Must fulfill all requirements for a "B" plus provide a clear extension to Dresser-Rand uses. The data acquisition system is capable of measuring ranges of data outside the normal operation of the donation compressor and into the vast products that Dresser-Rand offers. The user interface is easy to use and allows for collection of data from multiple runs by way of a database. Failure data has been collected by inducing faults of interest to Dresser-Rand and includes a basic comparision of data plots between normal operation and failure operation. Guidelines and documentation have been well maintained to allow for an easy transition over to future projects (master's or SD). The end system should allow for the ability to understand compressor responses (in the future).

23. EDGE™ Phase 0: Planning Required Resources

24. EDGE™ Phase 0: Planning Budget Information Budget set for this project is $8000 Mock Budget (Very Rough) ItemQuantityPriceTotal Temperature collection26501300 Pressure Collection2250500 Sound Collection1154 Accelerometer2185370 Flow Meter1588 power supply27701540 transmitter2300600 PCB2200400 external hardrive1150 wireless transmitters (calibration)25001000 trip funding2400800 7402

25. EDGE™ Issues and Risks Size, Noise, and Cost associated with machine. Operation of the Machine will Probably have to be done outside of normal school hours. Lead times on the acquisition of the actual piece of turbo-machinery and parts. Lead time on sensors and $$$ Integration of Control Systems Complexity of Data Signatures and Noise Confidentiality concerns Safety of Operation Limited EE’s and CE’s

26. EDGE™ Future Plan Where do you go from here? Complete necessary actions in acquisition of turbo-machinery. Location of Team Members (Potential) Secure Facilities 5 minute commercial

27. EDGE™ Why This Project Presents a challenging task for Senior Design members to complete with a complete coverage of topics taught through the school years. The project is important in the development of a relationship between RIT and Dresser-Rand Co. Will show off the cross functionality of the Senior Design process with a dependence on diverse teams.