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P14453: Dresser-Rand Compressor Bearing Dynamic Similarity Test Rig Subsystem Design Review

P14453: Dresser-Rand Compressor Bearing Dynamic Similarity Test Rig Subsystem Design Review. Project Team. Stakeholders. RIT: Researchers: RIT: Industry Engineers: Dresser-Rand:. MSD1 Team – 14453 Graduate/Masters Students William Nowak (Xerox). Dr. Jason Kolodziej

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P14453: Dresser-Rand Compressor Bearing Dynamic Similarity Test Rig Subsystem Design Review

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  1. P14453: Dresser-Rand Compressor Bearing Dynamic Similarity Test Rig Subsystem Design Review Rochester Institute of Technology

  2. Project Team Rochester Institute of Technology

  3. Stakeholders RIT: Researchers: • RIT: Industry Engineers: • Dresser-Rand: • MSD1 Team – 14453 • Graduate/Masters Students • William Nowak (Xerox) • Dr. Jason Kolodziej • Assistant Professor • (Primary Customer) • Dr. Stephen Boedo • Associate Professor • (Subject Matter Expert) • James Sorokes • Principal Engineer • Financial Support • Scott Delmotte • Mgr. Project Engineering • Point of Contact ? Rochester Institute of Technology

  4. Subsystem Design Review Agenda • Objective Statement • Review of Functional Decomposition • System Design Review Summary • Critical Subsystem Identification • Design / Analysis Plan • Engineering Analysis: • Test Bearing • Load Application • Lubrication System • Structural (Initial – Shaft Design, Support Bearing Selection) • Control System (Initial - System model/simulation) • Risk Assessment (Updated) • Milestones Chart (Updated) Rochester Institute of Technology

  5. Objective Statement • Objective: • Develop a bearing dynamic similarity test rig to more carefully investigate the dynamics of the Dresser-Rand floating ring main compressor bearings. • Design the rig such that it can incorporate all journal bearings for the purpose of fault detection research at RIT. Rochester Institute of Technology

  6. Functional Decomposition Review Rochester Institute of Technology

  7. Functional Decomposition:Running the Test Rochester Institute of Technology

  8. P14453 System Design Summary • Proposition: • Direct Actuation using 2 perpendicular EHA Units • DC Motor Driven • Direct Drive using a vibration dampening fixed coupling • Roller Bearing Support • Sleeve Side Lubrication Rochester Institute of Technology

  9. P14453 System Design Summary Shaft Coupling Bearing Shaft Drive Motor Support Bearings Load Block / Custom Bearing Housing Test Stand Test Bearing Oil Sump Hydraulic Cylinders Rochester Institute of Technology

  10. System Architecture Rochester Institute of Technology

  11. Critical Subsystem Identification Rochester Institute of Technology

  12. Design/Analysis Plan Rochester Institute of Technology

  13. Journal Bearing Analysis Initial calculations were performed in order to identify the coefficient of friction using Petroff’s Equation and the Sommerfeld Number which is used to identify bearing performance. Rochester Institute of Technology

  14. Journal Bearing Analysis Further study lead to calculations of Significant Angular Speed, based on Journal angular velocity, Bearing angular velocity, and Load Vector Angular Velocity. This information was used to determine static situation at each of 360 degrees of crank rotation based on actual compressor main bearing load data. Rochester Institute of Technology

  15. Journal Bearing Analysis Dr. Boedo explained that the analytical approach taken would be acceptable for static loading and had previously been used for dynamic loading. However, the mobility method of analysis is needed for dynamic loading order to find the minimum film thickness, or separation between the journal and sleeve. Rochester Institute of Technology

  16. Journal Bearing Analysis • Dr. Boedo used parameters that we developed in order to use a program to analyze the dynamics of our bearing. • The Parameters: • Shaft speed: 360 rpm • Bearing Dimensions • Oil specifications: • SAE 30 • 100 °C • 7 mPa-s Viscosity Rochester Institute of Technology

  17. Journal Bearing Analysis Dr. Boedo provided us with the following graph, which shows minimum film thickness vs. radial clearance based upon our criteria: Minimum safe film thickness Acceptable radial clearance based on film thickness Rochester Institute of Technology

  18. Load Application Analysis:Hydraulic Cylinders • Benefits: • Load Accuracy • Required Analysis (Incompressible Fluid) • Drawbacks: • Safety • Maintenance • From PRP and Markus’s Thesis: • Up to 900lbs (4000N) applied force • Up to 2000 rom shaft speed (33Hz) • Journal to sleeve clearance: 35 to 95 microns • Compressor Operating Rpm: 360rpm (Dr. Kolodziej) Rochester Institute of Technology

  19. Load Application Analysis: Hydraulic Cylinders • Parker Electro-Hydraulic Actuator (EHA) • Hybrid combining benefits of hydraulic cylinder and electric servo • Self-contained unit • Speed and Load Range • Size Rochester Institute of Technology

  20. Load Application Analysis: Hydraulic Cylinders • Calculations for Parker EHA (w/ Motor B and 0.327 gear): • Distance for Piston to move (conservative): • 95µm=0.00374"; 0.00374"*2= • 0.00748“ ≈0.01" (cushion) • Piston Speed from Graph ≈ 1.8in/s • Cycle time: • (0.01in)/(1.8 in/s)*2(extend & retract)= • 0.011secs/cycle • Actuator Frequency: • 1/(0.011 secs/cycle)= • 90 cycles/second = 90Hz Rochester Institute of Technology

  21. Load Application Analysis:Hydraulic Cylinders Rochester Institute of Technology

  22. Load Application Analysis:Hydraulic Cylinders • Challenges: • Are EHA’s load input based or displacement input based? • Response time to inputs • Piston Velocity varies with load • Extension load, as opposed to retract (Additional actuator(s)?){$$$} Rochester Institute of Technology

  23. Lubrication System analysis: • Oil Pressure • Adjustable from 10 – 25 psi • Measure 0 – 25+ psi • Oil Flow rate: • Estimated .36 GPH + flow • Oil Temperature: • -10°F - 135°F Input • Oil Storage/Capacity: • Up to 7 quarts • Oil Path: • Oil and chemical resistant pump • Oil and chemical resistant plumbing • Separate path with/without oil filter Journal Housing Oil pressure transducer Path branches Oil reservoir Oil filter Oil pump Rochester Institute of Technology

  24. Lubrication System analysis: • Oil Pressure: • Pump must supply 25psi + path head losses. From initial calculations pump must supply 26.58 psi total. • The path is restrictive however the low flow velocity (0.0172 fps) means the losses are minimal. • This pressure and flow rate is well within the selected pump’s operating parameters. Rochester Institute of Technology

  25. Lubrication System analysis: • SHURflo SLV10-AA41: • This pump operates within the desired operating range with an automatic start at 25 psi and automatic shutoff at 40psi. • The pressure sensing capabilities of the pump coupled with valving allows the feed pressure to be controlled (adjustable from 10 – 25 psi). • Polymer valving and diaphragms have good resistance to degradation from oil and other chemicals. • Pump can run dry and is self priming for worry free oil changing. Rochester Institute of Technology

  26. Lubrication System analysis: • Pressure adjustment: • Accomplished via pressure reduction valve, when feed side pressure reaches the desired pressure the valve closes. • The closed valve causes pressure to increase in the pump side pipe, at 40 psi the pump shutoff is triggered. As the oil feeds into the bearing the changing pressure causes the valve to re-open. This may cause small pressure fluctuations. • A hydraulic reservoir (pressurized) compartment can be used to prevent short-cycling. This will also reduce pressure fluctuations (if any exist). From Pump To System Nominal Pressure Pump-side Pressure System-side Pressure Rochester Institute of Technology

  27. Lubrication System analysis: From Pump • Oil path: • Paths will be made of specialized Excelon tubing. This transparent tubing is specially formulated to be resistant to oils and fuels, prevent plasticizer and chemical leeching, and maintain it’s flexibility. • The flow path will be divided and rejoined using two tee or vee branches. • Each branch will have a ball-valve to open or close the path, one path will be a straight path to the test bearing housing while the other runs oil through an oil filter before proceeding to the test bearing housing. To Housing OIL FILTER Rochester Institute of Technology

  28. Structural Analysis • Initial calculations on were done on the following: • Reaction forces on the support bearings • Support bearing life rating • Support bearing load rating Rochester Institute of Technology

  29. Structural Analysis • Support Bearings (Cylindrical roller bearing) • Maximum size = 2.75 • Basic Dynamic Load Rating = 11,000 lbf = 48930 N • Limiting Speed = 360 rpm Rochester Institute of Technology

  30. Structural Analysis Rochester Institute of Technology

  31. Control System Schematic Rochester Institute of Technology

  32. Control System Simulation Rochester Institute of Technology

  33. Updated Risk Assessment Rochester Institute of Technology

  34. MSD1 Milestones Chart Rochester Institute of Technology

  35. Problem Definition [09/10/13]: • Define problem • Define customer requirements • Define engineering requirements • Plan project • System Design Kick-Off [09/17/13]: • Problem definition completed • Begin concept development • Decomposition analysis • Risk assessment • Benchmarking concepts • System Design Review [10/01/13]: • System design completed • Meet with guides/panels/stakeholders • Select feasible system • Sub-System Design [10/08/13]: • Subsystem design and interactions • Requirement flow-down • Next level of decomposition analysis • Feasibility analysis • Subsystem Design Review [10/29/13]: • Subsystem design completed • Meet with guides/panels/stakeholders • Detailed Design & Component Selection Kick-Off [10/31/13]: • Fully completed drawings • Component list • Any FEA/Simulations • Risk assessment • Benchmarking plans • Preliminary DDR [11/19/13]: • Meet with guides/panels/stakeholders • Ensure that all design components are complete MSD1 Milestones Rochester Institute of Technology

  36. Preliminary DDR [11/14/13] • Analysis to support design complete • All factors affecting design considered • Drawings, schematics and flow charts complete • Perform next level of risk assessment • Complete Design [11/21/13]: • Full drawing package complete • Complete BOM • Simulation models complete • Risk assessment and mitigation complete • MSD II plan first draft complete • Final Detail Design Review [12/5/13]: • Proof of robust design provided • Expected performance vs. engineering reqs supplied • Test plan to verify performance • Identification of most complex sub-systems for build phase • Member specific weekly MSD II schedule complete • Gate Review [12/12/13 - 12/17/13]: • Budget prepared • Final design complete • Receive approval of customer to proceed with design MSD1 Detailed Design Milestones Rochester Institute of Technology

  37. Questions? Rochester Institute of Technology

  38. BACK-UP SLIDES Rochester Institute of Technology

  39. Customer Needs Rochester Institute of Technology

  40. Engineering Requirements Rochester Institute of Technology

  41. Pareto Analysis *link to House of Quality upon request: https://edge.rit.edu/edge/P14453/public/Problem%20Definition Rochester Institute of Technology

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