Sneha Rao – Project ManagerEdward Budriss – ME

Alex Scarangella – MEEdward Wolf – CE

Anna Cheung – ISE

Objective

Prepare installation document Create a system to monitor activity, facilitate

labs, and prepare for future health monitoring Develop lab procedures Ensure the compressor is safe for lab use by

students and faculty

Installation – Structural Integrity Created simulations in ANSYS to perform structural and

modal analysis to target areas of concern Modal analysis showed that structure would not be

affected In the test cell, .00402” deformation due to static load Initial simulation showed that floor was not structurally

acceptable

Installation – Structural Integrity Worked with PE to determine reinforcements

Chose two steel I-beams placed at the extremes of the skid to dissipate forces

Compressor skid was also modeled to determine deflection and factor of safety Yield strength for material of skid provided a factor of

safety of 4.56

Installation - Ventilation Based on heat coming off compressor and amount of

people in the room, calculated the air flow necessary Heat emitted into the room was previously calculated by

motor inefficiencies, and black body analysis, approx. 3000BTUs/hour

DescriptionSymbol

Value Units

Temp of Machine Shop Tshop 70 Fo

Max Temp. Tmax 80 Fo

Heat From Compressor qcomp 3000 BTU/hr

Heat Gen. From People* met 22BTU/hr-ft2

Avg. Exposed Skin Area Askin 2 ft2

Number of People in Cell npeople 15 #Specific Enthalpy Exiting Air hin 26.2 BTU/lbSpecific Enthalpy Entering Air⁺ hout 29.8 BTU/lbSpecific Volume of Air (exiting) 1/

13.71 ft3/lb

Relative Humidity of the Shop RH 60 %*Metabolic heat generation for a person standing, relaxed⁺From psychrometric chart negligible moisture added from people

hrBTUAmetnq skinpeoplepeople 66022215

hrBTUqqq peoplecomptotal 4000

CFMhh

qV

qhhV

Vmm

hmqhm

inoutout

totalout

totalinoutoutout

outoutoutin

outouttotalinin

2542.268.29

71.134000

Installation - Ventilation

Upon confirmation of drawings for present ventilation capabilities: Current ventilation system that contains GB-91

exhaust fan, 12” diameter ducts, EF-31 , and EF – 32 exhaust fans on the roof would be adequate if all equipment is available

Research an exhaust fan that is similar with 1/8 horsepower

Installation – Transportation/Mounting Work with Boulter Rigging Dresser-Rand → Boulter Rigging → RIT 45’ of transportation through Building 09 Load must be distributed over 60ft2 using skates Mount using shim, 12 mm grade 8 bolts, nuts, and steel

plates

Installation – Cooling Loop

Chilled water supply must be plumbed into the test cell Cooling system must remove 40,000BTU/hr Inlet coolant temperature needs to be maintained at 10°F above

ambient air temperature System includes:

Pump: 300 GPH, 115V, ½” Heat exchanger: ¾ NPT inch connection, 8x3.25x 2.25” Coolant tank: Poly storage tank 22x10x8” Immersion heater: 400W, ⅝” diameter, ½ NPT Flow meters

Installation – Cooling Loop

Installation - Acoustics

To ensure safety of operators in the test cell, performed acoustic analysis to determine the noise dosage

Assuming a typical lab situation, exposure of an hour would not require ear protection

Assuming extended maintenance, exposure of 8 hours would require ear protection

NoiseDosage100((1

183) (

1

75.8) (

1

16))

NoiseDosage8.12

Noise Dose100(c1

t1 c2

t2 ... cn

tn)

tn 8

2(L 90)

5

Lab Situation

Extended Maintenance

NoiseDosage100((8

183) (

8

75.8) (

8

16))

NoiseDosage64.9

Installation – Interface

Chose sensors that will facilitate educational labs and prepare the compressor for future health monitoring

Specified ideal positions and mounts to assure versatility Researched DAQs that will integrate smoothly with the

selected sensors

Installation – Sensors

Position Sensor Model # Mounting

A X-axis Velocity PCB VO622A11

Stud/Magnetic Mount

A X-axis Accelerometer

PCB 623C00 Stud/Magnetic Mount

B Inner Bore Pressure

PCB 102A21 Bore Hole

C Z-axis Accelerometer

PCB 623C00 Stud/Magnetic Mount

D Y-axis Velocity PCB VO622A11

Stud/Magnetic Mount

D Y-axis Accelerometer

PCB 623C00 Stud/Magnetic Mount

Installation – Sensors

Position Sensor Model # Mounting

E Inlet Air Pressure PCB 101A05 Stud Mount

F Tank Air Pressure PCB 102A21 Bore Hole

G Tank Air Temperature Omega RTD-NPT-72-E-DUAL-MTP

Bore Hole

H Outlet Air Temperature Omega RTD-805

Adhesive Mount

H Output Air Pressure PCB 102A21 Adhesive Mount

H Air flow meter Omega FTB-936

Pipe Fitting

I Water Inlet Flow Rate Omega FV101 Pipe Fitting

I Water Inlet Temperature Omega FV101 Pipe Fitting

J Outlet Water Temperature

Omega FV101 Pipe Fitting

J Outlet Water Flow Rate Omega FV101 Pipe Fitting

K Inlet Air Temperature Omega RTD-805

Adhesive Mount

Education – Thermal Fluids

Explores the concepts of isentropic compression

Utilizing a high sample rate pressure transducer located in the bore of the cylinder and a crank position sensor, we are able to generate real-time plots of pressure vs. volume

Compare real-time plots with the theoretical pressure vs. volume diagram

Education – Thermal Fluids Assuming adiabatic compression and negligible

pressure drop through the valves, a theoretical p-v diagram can be generated

Chart and plot volume values for a variety of pressure values between atmosphere and the maximum absolute pressure that the compressor achieves (use the equation for adiabatic compression and expansion for values between atmospheric and the maximum pressure)

VTDC,Outer 2.545

VTDC,Frame 0.795

VBDC,Outer 143.916

VBDC,Frame 142.167

P-V Diagram (Outer Side Cylinder)

0

10

20

30

40

50

60

-25 0 25 50 75 100 125 150

Volume(in^3)

Pre

ss

ure

(ps

i)

Education - Vibrations Create a theoretical model using vibration analysis Calculate the maximum deflection on the compressor Then using the data logged from the accelerometer

attached to the skid, measure the deflection on the skid. Compare the theoretical and experimental data. Include

the ANSYS analysis.

Test Plans Usability Tests E-Stop

Prior to first run and During first run Lock-out Tag-out

Prior to first run, During first run, Removal and Reinstall of parts Air Flow Sound Levels Room Temperature Vibrations Lifting Capabilities

Supplying to Future Team

Calculations and Simulations Cooling Loop, Thermal Analysis, Ventilation, Acoustic,

ANSYS Installation Manual

Includes necessary contracted work, mounting of compressor, hardware needed, ventilation requirements, cooling loop, sensors, location for sensors, and DAQ

Safety Document Educational Labs Test Plans Planning Documents