MSD 1 P12453Detailed Design Review

Markus HolzenkampRobin Leili

Cody Anderson

04/18/23

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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

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Team MembersTEAM:Project Manager: Markus Holzenkamp (ME)Project Engineers: Cody Anderson (ME)

Robin Leili-Marrazzo (ME)

CUSTOMER:Dr. Jason Kolodziej, ME Department, RITDr. 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)

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Customer NeedsPriority Need

1 Learn RITDAQ capabilities and propose and implement improvements in code to generate p-v diagrams, time and frequency plots

1 Propose and install possible additional sensors to measure stage pressures, stage temperature, bearing temperature

2 Install Envision System

3 Select, install, and integrate encoder

99 Develop future undergrad/grad labs

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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

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Sample Engineering Specs (Updated)

Specification Unit of Measure

Marginal Value

Ideal Value

Actual Value

Encoder Resolution pulses per rev 1 1440 720 (x4)

crankshaft / encodershaft ratio 10 1 1

Encoder Lifetime cycles 100000 1000000 TBD

Voltage required by sensors V 120 24 8-30

Sensor Cost $ 1000 0 <300

Sensor Output V 0-5 0-5

Sample Rate of the RITDAQ Hz 0 <370kHz TBD

Total number of analog sensors # 0 <16 13

Total number of thermocouples # 0 <16 12

Pipe thread size ½”- ¾” NPT

1/8” – ¾” NPT

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Concept Selection04/18/23

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Risk Assessment04/18/23

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Risk Assessment04/18/23

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RITDAQChannel layout and sensor attachments

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DAQ Channel Layout (Analog)04/18/23

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DAQ Channel Layout (Analog)04/18/23

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Flow meter

How?•Insert in flex-hose section

Why?•Easy to modify layout•Cost efficient

Materials Needed:-hose clamps (x2)-Adapter (x2)

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Tank Pressure04/18/23

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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

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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

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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

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DAQ Channel Layout (Thermocouples)04/18/23

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DAQ Channel Layout (Thermocouples)04/18/23

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Inlet Coolant TemperatureHow?•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 pipeMaterials Needed:-T-Piece-Hose Clamp-Adapter for Thermocouple-Thermocouple fitting

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Cylinder Coolant Layout04/18/23

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Head Outlet Coolant Temperature04/18/23

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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

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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

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Tail Coolant Out Temperature04/18/23

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Tail Outlet Coolant Temperature

How?•Drill and tap hole in pipe. (4mm wall thickness)

Why?•Close to outlet •No mixing with other coolant flowsMaterials Needed:- Thermocouple fitting

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Tail Coolant Out Temperature

• Test strength of threading schedule 80 pipe.

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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 fittingMaterials Needed:- Fitting for Thermocouple

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Combined Outlet Coolant Temperature

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Measuring the temperature of the cooling pipes at various locations

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)

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Crankcase Oil Temperature

How?•Attach fitting with thermocouple in plugged hole in crankcase

Why?•No modification of existing structure

Materials Needed:-Adapter-Thermocouple fitting

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Crankshaft Bearing Temperature04/18/23

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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 accuratelyMaterials Needed:- Thermocouple fitting (x2)

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Bill of Materials 04/18/23

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Cost Breakdown

BUDGET $3000Sensors $1089Wiring $88

Hardware $243TOTAL COST $1420

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LabView Interface

Goals:•Clearly display compressor data•Time domain and Frequency domain•P-v diagram for forward stroke and backstroke

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PRELIMINARY TEST PLANS

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Sensor Tests

Means of testing sensor functionality•SigLab•Existing USB DAQ•RIT DAQ

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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

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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

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Preliminary MSD II Schedule04/18/23

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Questions?04/18/23

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