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Compressor Health Monitoring System Design Review

This detailed design review will cover the project background, customer needs, revised engineering specs, risk management, RITDAQ system, analog thermocouples, bill of materials, LabView VI interface, and test plan.

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Compressor Health Monitoring System Design Review

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  1. MSD 1 P12453Detailed Design Review Markus Holzenkamp Robin Leili Cody Anderson Detailed Design Review

  2. 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 Detailed Design Review

  3. 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) Detailed Design Review

  4. Customer Needs Detailed Design Review

  5. 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 Detailed Design Review

  6. Sample Engineering Specs (Updated) Detailed Design Review

  7. Concept Selection Detailed Design Review

  8. Risk Assessment Detailed Design Review

  9. Risk Assessment Detailed Design Review

  10. Channel layout and sensor attachments RITDAQ Detailed Design Review

  11. DAQ Channel Layout (Analog) Detailed Design Review

  12. DAQ Channel Layout (Analog) Detailed Design Review

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

  14. Tank Pressure Detailed Design Review

  15. 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 Detailed Design Review

  16. 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 Detailed Design Review

  17. 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 Detailed Design Review

  18. DAQ Channel Layout (Thermocouples) Detailed Design Review

  19. DAQ Channel Layout (Thermocouples) Detailed Design Review

  20. 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 Detailed Design Review

  21. Cylinder Coolant Layout Detailed Design Review

  22. Head Outlet Coolant Temperature Detailed Design Review

  23. 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 Detailed Design Review

  24. 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 Detailed Design Review

  25. Tail Coolant Out Temperature Detailed Design Review

  26. 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 Detailed Design Review

  27. Tail Coolant Out Temperature • Test strength of threading schedule 80 pipe. Detailed Design Review

  28. 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 Detailed Design Review

  29. Combined Outlet Coolant Temperature Measuring the temperature of the cooling pipes at various locations Detailed Design Review

  30. 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) Detailed Design Review

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

  32. Crankshaft Bearing Temperature Detailed Design Review

  33. 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) Detailed Design Review

  34. Bill of Materials Detailed Design Review

  35. Cost Breakdown Detailed Design Review

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

  37. Detailed Design Review

  38. Preliminary Test Plans Detailed Design Review

  39. Sensor Tests Means of testing sensor functionality SigLab Existing USB DAQ RIT DAQ Detailed Design Review

  40. 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 Detailed Design Review

  41. 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 Detailed Design Review

  42. Preliminary MSD II Schedule Detailed Design Review

  43. Questions? Detailed Design Review

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