Reciprocating Compressor Installation and Validation

1. Reciprocating Compressor Installation and Validation MSD I - 11452 • John Blamer – Team Leader • Promit Bagchi • Elliot Kendall • Matthias Purvis

2. Agenda • Background – 2 min. • Project scope – 2 min. • Deliverables – 2 min. • Customer Needs – 3 min. • Objective Tree - 3 min. • Engineering Specifications – 2 min. • House of Quality – 2 min. • Ranked Engineering Specs – 2 min. • IPO (Input-Process-Output) – 4 min. • Installation – 8 min. • Delivery • Completed Tasks & Current state • Tasks to be Completed • Checklists • Concept Selection – 20 min. • Vibration Reduction • Mount Method, Adapter Plate • Calculations • Coolant System • Calculations • Risk Assessment – 4 min. • Future Plan - 4 min.

3. Background • Continuation of SD group P09452 • Reciprocating Compressor donated to RIT by Dresser-Rand • To be installed in Machine Shop • For Research and Educational purposes • P09452 did significant preparation work • Shipped from D-R facility in India • Should arrive in Port of New York on October 25th • Trucked to Boulter Rigging -> RIT

4. Project Scope • Understand compressor • Basic operation • Hardware • Understand installation needs • Vibration isolation • Cooling system • After install, focus on education and Beginning of Life characterization

5. Deliverables • Have the reciprocating compressor fully functioning by the end of Fall quarter • Implement a preliminary DAQ system already owned by RIT • Measure/document beginning of life characterization data for the compressor • Review, test, and validate the Thermodynamics and Vibration labs created by P09452

6. Customer Needs

7. Objective Tree

8. Objective Tree

9. Objective Tree

10. Objective Tree

11. Objective Tree

12. Engineering Specs

13. House of Quality

14. Ranked Engineering Specs

15. IPO (Input, Process, Output) – Broad Overview Outputs Inputs Ease of use Customer Needs Process Validation tests Fully functional compressor Delivery Beginning of life characteristics DAQ system Implementation Installation Education

16. IPO (Input, Process, Output) – Detailed View Outputs Inputs Ease of use User Manual Customer Needs Dr. Kolodziej Dr. Hensel Process Validation tests Dresser-Rand RIT faculty Fully functional compressor Boulter Delivery Beginning of life characteristics DAQ system Implementation Failure Diagnostics Installation Vibrations Lab Attach dampers to unit & bolt to floor E-Stops & Electricity Thermal Fluids Lab Education Cooling System Future Labs Lattice dampers In-Class Uses Electrician LORD Corp. RIT FMS Demonstration/Discussion Assignments System Analysis & Research Review & validate previous project

17. Installation – Delivery Plan • Work with Boulter Rigging • Dresser-Rand → Boulter Rigging → RIT • 45’ of transportation through Building 09 • Ensure a clear path • Load must be distributed over 60ft2 using skates

18. Installation – Completed Tasks • HVAC - Installed • Supply Ductwork • Exhaust • Electrical Components - Installed • Supply Box • E-Stop Button • Electrical Receptacles on each wall • Light Switches • Coolant System – Installed • U-Tube Heat Exchanger • Chilled Water Supply & Return • Delivery Preparation - Complete • Entrance Path Selected • Structural Reinforcement

19. Installation – Current State • Electrical • Ventilation • U-Tube Heat Exchanger

20. Installation – Tasks to be Completed • Vibration Isolation System • Finalize mounting system design. • Coolant System • Coolant System Design Finalization • Acquire and Install: • Pump • Piping • Reservoir • Heating Element • Thermostatic Valve • Flow Control Valve

21. Installation - Checklists • Pre-Arrival Checklist • Order cooling system components and hardware • Fabricate damper adapter plates • Contact Boulter to verify delivery procedures and schedule • Contact and verify past PE work • Post-Arrival Checklist • Drill mounting holes in skid • Thorough visual inspection for damages or abnormalities • Cooling system installation • Verify compressor specs (hp, discharge psi, etc.)

22. Concept Selection – Vibration Isolation Primary Options Option 1: Bolt unit directly to floor Option 2: Place directly on floor Compressor Frame Compressor Frame Shop Floor Shop Floor Bolt Option 3: Place unit on concrete slab and rubber mat Option 4/5: Mount to vibration dampers Compressor Frame Compressor Frame Concrete Slab Shop Floor Rubber Mat Shop Floor Vibration Mounts Bolt

23. Concept Selection – Vibration Isolation Secondary Options Option 6: Shock and Spring Option 7: Recycled Tire Mounts Compressor Frame Compressor Frame Shop Floor Shop Floor Option 8: Auto Motor Mounts Option 9: Hockey Pucks Compressor Frame Compressor Frame Shop Floor Shop Floor

24. Concept Selection - Vibration Isolation Preferred Method

25. Installation - Transmissibility Calculations

26. Installation - Vibration Isolation Calculations Equations

27. Concept Selection – Mount Adapter Plate for LORD dampers Bolt adapter plate to I-Beam I-Beam Web Bolt holes to floor Bolt adapter plate to damper

28. Concept Selection – Mount Adapter Plate for LORD dampers Compressor Frame Adapter Plate LORD Damper To be drilled and bolted to frame

29. Concept Selection – Cooling System Layout #1: Immersion Heater Immersion Heater

30. Concept Selection – Cooling System • Layout #2: No Heater

31. Concept Selection – Cooling System • Layout #3:Heater Wrap Heater Wrap

32. Concept Selection – Cooling System • Layout #4: In-Line Heater In-Line Heater

33. Concept Selection – Cooling System In Line Heater No Heater Immersion Heater Net Score

34. Component Selection – Heating Element • Assumptions: • 10 degrees temperature rise • Four gallon reservoir

35. Installation –Cooling System Calculations

36. Concept Selection– Cooling System Flexible Plastic Copper

37. Installation –Cooling System Calculations

38. Component Selection – Cooling System • ¾” Silicone Tubing • Pump • 3 way Thermostatic Valve

39. Risk Assessment

40. Risk Assessment

41. Future Task Plans

42. Future Task Plans

43. Questions?