Garry Studley (Mechanical Engineering)

1. Concept Level Project PlanP08452 – Fault Detection and Diagnosis in Rotating Equipment for the Energy Industry Garry Studley (Mechanical Engineering)

2. 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.(?) Dave Hathaway (Mechanical Engineering) I would choose Dave due to the impact that the equipment may have on RIT and issues surround the facility housing the equipment. • Primary Customer • Scott Delmotte, Dresser-Rand, Title (?) – This is confirmed (Possibly working with Joe Tezca).

3. Phase 0: PlanningMission Statement Product Description Design and build a health monitoring system for some piece of turbo machinery (most likely a compressor). The system would detect impending failure, operation outside design specifications, and possible performance issues. Common sources of failure will be collected and compiled from customer knowledge on the issue. These sources will then be addressed. Key Business Goals The primary business goals of this product are to • 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 in hopes that the product would be used in support of the operation of turbo machinery. Future plans of the product could be mass implementation on the turbo machinery (oil) industry. Could offer replacement parts/services sooner on all machines in the industry. Secondary Market Secondary markets could include sale to Oil Pumping Companies, regardless of the brand of turbo machinery equipment used. These companies may want to monitor own machines to prevent any shutdowns/failures or to gain knowledge on which parts to replace during future scheduled shutdowns. Stakeholders Stakeholders in the design of our product include the following: End Users: Dresser-Rand, Power Plants, and Major Oil Companies Developer: RIT (could possibly lead to a future fault detection lab) Society: Environment (efficiency) and Oil Production Machine Suppliers: Dresser Rand and other companies Machine Operators: In the field/testing at Dresser-Rand Machine Inspectors/Field Service Representatives/Assembly Men: Hired by Dresser-Rand/Oil Companies

4. Phase 0: PlanningStaffing Requirements Mechanical Engineers 3 Mechanical Engineers would be primarily responsible for learning and determining what causes of failure are most prominent and the biggest cause of lost money/time. They would also determine what possible indicators could be used to trigger a response from the health monitoring system. Suitable backgrounds would be strong in Thermodynamics, Fluid Mechanics (Transport), Mechanics (Design of Machine Elements), Material Science, etc. I have not spoken with any mechanical engineers but would have the best means to recruit students in this field. Electrical Engineers 1 or 2 These engineers could help develop the integration of the project between the mechanical component and the health monitoring system. The health monitoring system might have electrical components that could be crucial to proper operation. The electrical background required might include advanced circuits and some type of control systems background (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 or 2 Industrial Engineers would help compile and implement the failure/fault data into the health monitoring system. They would be particularly useful with their experience in implementing people, knowledge, and systems on such fields as the turbo machinery industry. The industry itself is very much an industrial field. I have had no contact with any Industrial Engineers. Computer Engineers 0 or 1 I do not see a major need where I would need a computer engineer to perform any tasks on this project. Any programming that may need to be done on the health monitoring system could probably be done in Labview. Might need one if the system used was complex. Business Majors 0 or 1 A Business Major could help develop a business plan for the product which is new in this field. They would have to have a strong background in technology management and innovation (developing new products for existing markets). I have not spoken with anybody in this department but I am currently taking a class, introduction to technology management, in which I could maybe recruit some students.

5. Phase 0: PlanningResource Requirements People The project heavily relies on people within the Dresser-Rand organization. These would include machine operators, designers, inspectors, and field service representatives. The vast knowledge of these individuals will be primarily be used in developing the fault detection system. People within RIT will be crucial as they are the ones overseeing the project and the machinery involved. RIT is providing the space and the means for the project. Environment This is a major concern for the project as the proper laboratory is required that can house a piece of turbo machinery equipment. Proper inlet conditions are needed as well as handling exhaust gases. Problems with the equipment would need to be properly serviced and fixed if needed. Health and Safety will be an issue as these machines can be rather large, noisy, and sometimes run at high RPM. Equipment Equipment needed would be the actually piece of turbo machinery that would have the fault detection system implemented on it. This would also include the piece of equipment that would drive the machine and any piping that would be needed for oil or any other fluids. Equipment would be needed to service the machine such as engine hoists, proper tools (sockets, pipe wrenches, etc.), and any operation manuals. Inlet air supply, exhaust capability, power requirements and drainage would be needed. Installation of the machine will be important as there is such a short time frame to work with. Once the actual piece of turbo machinery is acquired for the project, the rest of the equipment would be obtained. No commitment has be assured as of yet. Materials Materials that might be needed are not yet clear to me. First of all the actual piece of turbo machinery would be needed. Also, any tools to service the machine and oil supplies would be used in the operation of the machine. Spare parts would also be necessary for any faults that occur while at RIT. Someway to lift heavy individual pieces such as flanges would also be needed. Sensors used in the health monitoring system would also be critical to determining what faults the machine is having. Any other types of mechanical/electrical devices and their components used in the fault detection would need to be obtained. The machine and any components would need to be purchased during DPM (in process right now).

6. Phase 1: Concept DevelopmentIdentify Customer Needs - Interviews Primary Customer(s) Dresser-Rand I plan on interviewing the primary contact, Scott Delmotte. Others include Joe Tezca (Dresser-Rand employee with experience related to this project) and other engineers at Dresser-Rand. I may also interview inspectors, machine operators, and field service representatives. I plan on refining this list with my Dresser-Rand contact. Other Stakeholder(s) RIT/Oil Companies/Power Plants I plan on interviewing my faculty guide, Margaret Bailey about her experience with possible performance issues. Other possible interviews may include contacts at offshore platforms or power plants where this type of equipment is used. These contacts would be obtained through the Dresser-Rand contact. 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. Phase 1: Concept DevelopmentIdentify Customer Needs - Benchmarking Competitive or Cooperative Solutions Impact Automated Equipment Fault Detection and Prediction Uses standard/existing industrial sensors: Pressure, Temperature, Vibration, Flow, and Acceleration. Identifies and reports component wear and fatigue. Evaluates machinery health, degradation modes, and allows for feedback to machine operators. Operating efficiencies could be evaluated. (www.impact-tek.com/Engineering/Category.aspx?cat=83) I would bring details on this system and the capabilities that it provides for its customer. Purchasing of such a system might be costly but viewing brochures on the equipment might be sufficient. Each member of the team might look at the information/components that is related to their field of expertise. Internet Search Possible Reciprocating Compressor used: http://www.grainger.com/Grainger/categories/pneumatics-and-hydraulics/air-compressors-and-vacuum-pumps/stationary-electric-air-compressors Possible Centrifugal Compressor used: http://www.air.irco.com/IS/product.asp-en-12996 Distributor of Used Turbo machinery: www.LCEC.com Competitors: http://www.impact-tek.com/Engineering/Category.aspx?cat=83 Technical Literature Search Compendex: Failure investigation of blade and disk in first stage compressor. Fatigue failure of a centrifugal compressor. Fatigue Failures of Compressor Impellers And Resonance Excitation Testing. Fault Detection of Rotating Machinery Using Model Based Techniques

8. Phase 1: Concept DevelopmentIdentify Customer Needs - Interpret Needs Statements: • Reduce undesired shutdown times associated with faults and failures. • Allow ample time to notify technicians that parts need replaced during scheduled shutdown times. • Increase performance by identifying components that are not behaving properly. • Improves health and safety of machine and workers. Graphical Interpretation • Affinity Diagram Clouds (filled in as interview occurs) - E:\DPM\AffinityDiagram_P08452.vsd • People, Equipment, Resources, Technology, etc. Will be done after interview occurs. Organize the Needs into a Hierarchy • Will be done after interview occurs. Establish the Relative Importance of the Needs • Will be done after interview occurs. Reflect on the Results and the Process • Will be done after interview occurs.

9. Future PlanWhere do you go from here? I will be conducting interviews with employees within Dresser-Rand, starting with either Scott Delmotte or Joe Tezca. Any other Dresser-Rand employees recommended by Scott Delmotte will be contacted and interviewed. Also, Dr. Bailey and I will be meeting to go over her interpretation of the project in detail. She will also attend a meeting between Joe Tezca and myself to determine the best piece of equipment for the project. The type of turbo machinery used will be determined and purchased by Dresser-Rand and includes determining the proper facility to keep this piece of equipment at RIT. The structure of the project should start to occur with a definite goal being set. Talks may occur with other stakeholders. Acquisition of additional tools and equipment/parts to assist operation of the turbo machinery will happen. In depth needs assessment will take place after these customer interviews occur. Further benchmarking of existing products and technologies will take place.