Transcript 11/6/2015 MSD 1 P12453 Detailed Design Review Markus Holzenkamp Robin Leili Cody Anderson Detailed Design Review.

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MSD 1 P12453
Detailed Design Review
Markus Holzenkamp
Robin Leili
Cody Anderson
Detailed Design Review
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Agenda
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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 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)
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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
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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
Encoder Resolution
Unit of Margin Ideal Actual
Measure al Value Value Value
pulses per
rev
crankshaft / encodershaft ratio
1
1440
720 (x4)
10
1
1
Encoder Lifetime
cycles
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
½”- ¾”
NPT
12
1/8” –
¾” NPT
Pipe thread size
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100000 1000000
TBD
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Concept Selection
Concept Concept Concept
Selection Selection Sketch
(week 3) (week 7) (week 8)
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Risk Assessment
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Risk Assessment
Detailed Design Review
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Channel layout and sensor attachments
RITDAQ
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DAQ Channel Layout (Analog)
Detailed Design Review
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DAQ Channel Layout (Analog)
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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)
Detailed Design Review
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Tank Pressure
Detailed Design Review
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Tank Pressure
How?
• Use Rosemount
Alphaline 1151
• Mounted on
compressor base
• Connected with
pressure tubing
Detailed Design Review
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
Detailed Design Review
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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
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?
• Attach T-Piece between
flex hose and steel flange
Detailed Design Review
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
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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?
• Attach fitting to plugged
hole and insert
thermocouple directed
at top outlet
Detailed Design Review
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 Temperature
Detailed Design Review
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Tail Outlet Coolant Temperature
How?
• Drill and tap hole in
pipe. (4mm wall
thickness)
Detailed Design Review
Why?
• Close to outlet
• No mixing with other
coolant flows
Materials Needed:
- Thermocouple fitting
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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?
• Drill and tap hole in
bottom of flow sight
Detailed Design Review
Why?
• Close after all 3 coolant
outlets combine
• Sufficient wall thickness
to secure enough
threads for fitting
Materials Needed:
- Fitting for Thermocouple
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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?
• 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
Detailed Design Review
Why?
• No modification of
existing structure
Materials Needed:
- Adapter
- Thermocouple fitting
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Crankshaft Bearing Temperature
Detailed Design Review
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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
Detailed Design Review
Why?
• Does not alter bearing
function
• Will show trends of
bearing temperature
accurately
Materials Needed:
- Thermocouple fitting
(x2)
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Detailed Design Review
Bill of Materials
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Cost Breakdown
BUDGET
Sensors
Wiring
Hardware
TOTAL COST
Detailed Design Review
$3000
$1089
$88
$243
$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
Detailed Design Review
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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
Detailed Design Review
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Preliminary MSD II Schedule
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Questions?
Detailed Design Review