P08452 Reciprocating Compressor Installation, Revamp, and Interface

1. Sponsored by: P08452 Reciprocating Compressor Installation, Revamp, and Interface • Background • Previous service aboard • U.S. Navy aircraft carrier • (U.S.S. Enterprise) • Utilized for: • turbine/diesel starting • weapon augmentation • liquid oxygen reservoirs • 6-stages, 3000 psi, 75 HP • Cost: 1970 ~ $400,000 Team Picture Project Statement A six-stage compressor will be donated by Dresser-Rand for research usage by future student teams. It first must be installed at RIT, modified for safe and appropriate use in a college environment, and provided with a suitable data acquisition interface. From left to right: Garry Studley (ME), Kiernan French (ME), Chris Neitz (CE), Dave Rigolo (ME), Alec Jarvie (ISE), and Dr. Margaret Bailey (Faculty Guide ME) Specifications for Installation Test Cell Layout Installation • Designed and prepared the installation guidelines and test cell setup to provide for safe operation. • Ensured room layout allowances for full access to all machine components. • Analyzed test cell setup to mitigate vibration, acoustic, and structural concerns. • Vibration dampening mounts. • Tested current acoustic dampening of test cell. • Structural engineering analysis of room capabilities. • Developed Operation and Maintenance Manual for compressor. 12 Vibration Spring Mounts Acoustic Verification Stages for Removal Revamp • Calculated reduced inputs and outputs of compressor. • Exit pressure reduced from 3000 psig to 100 psig. • Mechanical power reduced from 62 HP to 25 HP. • Electrical current input reduced from 90.3 Amps to 38 Amps. • Necessary heat removal reduced from 29 Btu/sec to 11 Btu/sec. • Open loop cooling system converted to fresh water. • 50 gpm of salt water converted to 5 to 15 gpm of fresh water. • Removed unneeded heat exchangers from cooling loop. • Test Cell room air can be cycled in approx.4 minutes. • Redirection of air flow from 2nd stage outlet to overall outlet. • Counter weights added to balance reciprocating load. • Replaces 3rd through 6th stage pistons that were removed. • Revamp instructions created for implementation of changes. Sample Counter Weight Assembly Specifications for Revamp Interface • Accounts for fault detection needs in future projects. • Easy integration into data acquisition needs. • Equipment and budget suggested. • Intuitive control panel which displays the current value of each data set. • Status lights which show if the data is within a safe limit. • Graphs to display recent information trends. Specifications for Interface Acknowledgements Dr. Margaret Bailey, Faculty Guide Dr. Mark Kempski, Faculty Consultant Dave Hathaway, Project Consultant Rob Kraynik, Project Consultant Steve Koscial, Project Consultant Ryan Crittenden, RIT Facilities Electrician Dr. Edward Hensel, ME Department Head Scott Delmotte, Manager Development Engineering Joe Tecza, Manager Project Engineering Bob Smith, Project Manager for Military Group Ray McKinney, Dresser-Rand Control Systems Mike Bunce, Director of Recruiting Andy Blide, Engineer Technician David Decker, II, Training Specialist Allan Kidd, Director of Emerging Technologies