MSD 1 P12453 Detailed Design Review

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					1/21/2014                                           1




                          MSD 1 P12453
                      Detailed Design Review
                                Markus Holzenkamp
                                    Robin Leili
                                 Cody Anderson

       Detailed Design Review
1/21/2014                                       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
1/21/2014                                                                                           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
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                                 Customer Needs
       Priority     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




        Detailed Design Review
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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

        Detailed Design Review
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        Sample Engineering Specs (Updated)
                                                       Unit of Margin Ideal Actual
                                  Specification
                                                       Measure al Value Value Value
                                                       pulses per 
                            Encoder Resolution                         1     1440      720 (x4)
                                                          rev
                     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
                                                                             ½”- ¾”  1/8” – 
                                 Pipe thread size
                                                                              NPT    ¾” NPT 


        Detailed Design Review
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                                 Concept Selection




        Detailed Design Review
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                                Risk Assessment




       Detailed Design Review
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                                Risk Assessment




       Detailed Design Review
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        Channel layout and sensor attachments

        RITDAQ


       Detailed Design Review
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              DAQ Channel Layout (Analog)




        Detailed Design Review
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              DAQ Channel Layout (Analog)




        Detailed Design Review
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                                Flow meter
     How?                          Why?
     •Insert in flex-hose section  •Easy to modify layout
                                   •Cost efficient

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



       Detailed Design Review
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                                Tank Pressure




       Detailed Design Review
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                                Tank Pressure
     How?                              Why?
     •Use Rosemount Alphaline          •Already have sensor
     1151                              •Easy to place T-Piece 
     •Mounted on compressor            before analog gage
     base
     •Connected with pressure          Materials Needed:
     tubing                            -T-Piece
                                       -Adapter
                                       -Thermocouple fitting

       Detailed Design Review
1/21/2014                                                     16



                            dP across orifice tank
     How?                              Why?
     •Use Rosemount sensor             •No room constraints
     •Mount in basement with           •Out of the way
     tank
                                       Materials Needed:
                                       -Hardware
                                       -Adapter (x2)
                                       -Elbow


       Detailed Design Review
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                      Photocraft HS20 Encoder
     How?                         Why?
     •Use included mounting       •No modifications to 
     bracket to attach to oil     existing structure
     pump housing


                                  Materials needed:
                                  - 7/16-14 Bolt 3in long
                                  - 7/16-14 nuts


       Detailed Design Review
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      DAQ Channel Layout (Thermocouples)




        Detailed Design Review
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      DAQ Channel Layout (Thermocouples)




        Detailed Design Review
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                   Inlet Coolant Temperature
     How?                         Why?
     •Attach T-Piece between      •No modifications to 
     flex hose and steel flange   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
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                        Cylinder Coolant Layout




       Detailed Design Review
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       Head Outlet Coolant Temperature




       Detailed Design Review
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       Head Outlet Coolant Temperature
     How?                          Why?
     •Attach fitting to plugged    •No modification of 
     hole and insert               existing structure
     thermocouple directed at      •Measures right at the 
     top outlet                    outlet 
                                   Materials Needed:
                                   -Thermocouple fitting
                                   -Adapter


       Detailed Design Review
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                           Center Outlet Coolant 
                               Temperature
     How?                             Why?
     •Attach fitting with             •No modification to 
     thermocouple to plugged          existing structure
     hole adjacent to outlet          •No losses

                                      Materials Needed:
                                      -Adapter
                                      -Thermocouple fitting


       Detailed Design Review
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              Tail Coolant Out Temperature




       Detailed Design Review
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            Tail Outlet Coolant Temperature
     How?                            Why?
     •Drill and tap hole in pipe.    •Close to outlet 
     (4mm wall thickness)            •No mixing with other 
                                     coolant flows
                                     Materials Needed:
                                     - Thermocouple fitting




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




       Detailed Design Review
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                         Combined Outlet Coolant 
                              Temperature
     How?                            Why?
     •Drill and tap hole in          •Close after all 3 coolant 
     bottom of flow sight            outlets combine
                                     •Sufficient wall thickness 
                                     to secure enough threads 
                                     for fitting
                                     Materials Needed:
                                     - Fitting for Thermocouple


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




       Detailed Design Review
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     Coolant Temperature Before and After 
                   Chiller
     How?                          Why?
     •Insert T-Piece between       •Easy to add piping at this 
     flex hose and Chiller inlet   place

                                   Materials Needed:
                                   -T-Piece (x2)
                                   -Adapter (x2)
                                   -Thermocouple fitting (x2) 


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



       Detailed Design Review
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            Crankshaft Bearing Temperature




       Detailed Design Review
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            Crankshaft Bearing Temperature
     How?                           Why?
     •Drill into crankcase until    •Does not alter bearing 
     just before bearing journal    function
     •Insert thermocouple to        •Will show trends of 
     measure temperature of         bearing temperature 
     crankcase at that point        accurately
     •Assistance from Dresser-      Materials Needed:
     Rand                           - Thermocouple fitting 
                                    (x2)


       Detailed Design Review
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                                 Bill of Materials    34




        Detailed Design Review
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                                 Cost Breakdown
                              BUDGET       $3000
                               Sensors     $1089
                               Wiring        $88
                              Hardware      $243
                             TOTAL COST    $1420




        Detailed Design Review
1/21/2014                                             36




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




        Detailed Design Review
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       Detailed Design Review
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        PRELIMINARY TEST PLANS


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




        Detailed Design Review
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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



        Detailed Design Review
1/21/2014                                              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
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                Preliminary MSD II Schedule




       Detailed Design Review
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                                 Questions?




        Detailed Design Review

				
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