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

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

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  1. P14453: Dresser-Rand Compressor Bearing Dynamic Similarity Test Rig Detailed 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. Detailed Design Review Agenda • Objective Statement • Problem Definition Review • System/Subsystem Design Review • Concept Selection • Top Level Layout • Load Application System Design/Selection • Test Bearing Design • Lubrication System Design • Structural Support System Design • User Interface Design • Drivetrain System Design • Detailed Bill of Materials • Updated Risk Assessment • MSD II Plans/Next Steps • Test Plans • Discussion Rochester Institute of Technology

  5. Objective Statement • Objective: • Develop a journal 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 a variety of journal bearings for the purpose of fault detection research at RIT. Rochester Institute of Technology

  6. Customer Needs Rochester Institute of Technology

  7. Engineering Requirements Rochester Institute of Technology

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

  9. Functional Decomposition Rochester Institute of Technology

  10. System Architecture Rochester Institute of Technology

  11. Top Level Layout Rochester Institute of Technology

  12. Top Level Layout Rochester Institute of Technology

  13. Load Application Selection Summary Rochester Institute of Technology

  14. Piezoelectric Load Application Summary • Piezoelectric Load System Attributes: • Load Accuracy • Load Repeatability • Load Range • Dynamic loading • Compact System design • Variable load profiles • Meets all of PRP requirements • Piezoelectric Load System Drawbacks: • $$$ COST $$$ • Programming for controls/user interface • Power system • Availability • Complex system design • Actuator pre-load required Rochester Institute of Technology

  15. Lead Screw Load Application Summary • Lead Screw Load System Attributes: • Load Range • Cost • Simple control • Simple Analysis • Load accuracy (gear box) • Load repeatability (gear box) • Lead Screw Load System Drawbacks: • Weight • System size (chain drive), adds cost • Dynamic loading not feasible • System design • Load accuracy (chain drive) • Load repeatability (chain drive) Rochester Institute of Technology

  16. Electrohydraulic Load Application Summary • Electrohydraulic Load System Attributes: • Compact size; one piece housing • Self-contained unit • Load range • Speed range • Electrohydraulic Load System Drawbacks: • Mounting (designed to pivot) • Load control, Accuracy, and Repeatability • Power requirements • Dynamic loading not feasible • High cost for minimal capability • No benefit to future projects • Slow response time Rochester Institute of Technology

  17. Pneumatic Load Application Summary • Pneumatic Load System Attributes: • Compact size • Simple controls • Simple Analysis • Cost • Load Range • Load Accuracy • Load Repeatability • “Free” power system (air supply) • Pneumatic Load System Drawbacks: • Dynamic loading not feasible • Slow response time • Minimal adaptability to future projects Rochester Institute of Technology

  18. Pneumatic Actuation Design • High load analysis (6” bore actuator) • Low load analysis (3.25” bore Actuator) Rochester Institute of Technology

  19. Test Bearing • Journal Bearing Attributes: • Outside Dimensions: 2.750” Long X 3.129” Dia. • C93200 Brass (SAE 600) • Oil feed port with oil groove • Supplier: Bunting Bearing Rochester Institute of Technology

  20. Test Bearing Housing • Journal Bearing Attributes: • Allows mounting of all required components • Oil inlet and outline lines • Horizontal and vertical actuators • Structurally rigid • Adaptable to different journal bearing sizes without major modifications Rochester Institute of Technology

  21. Lubrication System • Component list: • Oil Reservoir • Oil Filter Housing • Oil Filter • SHURflo Pump • Charge Tank • Adjustable Pressure Regulator Valve • Oil Inlet Line • Test Bearing Housing • Oil Return Line Rochester Institute of Technology

  22. Lubrication System • Capabilities: • 1 gpm maximum flow rate • Automatic shutoff in overpressure situations • 18 micron oil filtration system using standard automotive filter • 5 quart oil capacity • Charge Tank • Adjustable Pressure Regulator Valve • Fully adjustable oil pressure control valve included Rochester Institute of Technology

  23. Structural Support System • Component list: • Table Base • Table • Horizontal Cylinder Mount • Vertical Cylinder Risers (2) • Shaft Couplings • Motor Vibration Mat • Bearing Risers Rochester Institute of Technology

  24. Structural Support System • Design Considerations: • Minimum factor of safety 1.8 on Horizontal Cylinder Coupling • Maximum Vertical Deflection in Vertical Cylinder Risers of 3.5 microns • Table first resonant frequency of 162 Hz Rochester Institute of Technology

  25. Drive System • Component list: • Leeson DC Motor • R+W Bellows Type Shaft Coupling • Shaft • SealMaster Pillow Block Roller Bearings Rochester Institute of Technology

  26. Drive System • Design Considerations: • Minimum factor of safety of 5.37 on shaft • Maximum shaft deflection of 5 microns • Shaft first resonant frequency of 259 Hz • Coupling features: • Torsionally rigid • Backlash free power transmission • Allows for shaft misalignment Rochester Institute of Technology

  27. User Interface Rochester Institute of Technology

  28. Bill of Materials Rochester Institute of Technology

  29. Risk Assessment Rochester Institute of Technology

  30. MSD II Plans • Subsystem Level Prep/Build (1/28 – 2/6) • Discussion board to capture issues • Testing resources/test bench setup • Test Plan and Project Plan • Prepare for Critical Design Review (If failed gate review) • Build/Test: Subsystem Level (2/11 – 2/27) • Build/Test subsystem components • Issues on Discussion board • Subsystem Functional Demo • Update Test Plan • Build/Test/Integrate: Subsystem and System Level (3/4 – 3/20) • Build/Test/Integrate subsystem and system components • Preliminary Integrated System Functional Demo • Update Test Plan • Complete initial technical paper outline • Build/Test/Integrate: Systems Level (4/1 – 4/17) • Prepare technical paper • Full integrated system demo with Customer. • Complete Project Poster • Verification and Validation (4/22 – 5/8) • Complete testing • Complete Paper and Poster • Complete documentation/updates to EDGE • Prepare Elevator Speech • Participate in Imagine RIT • Prepare Final Presentation • Final Presentations (5/13 – Exams) • Poster Presentation and Open House • Prepare for Gate Review • Finalize EDGE Rochester Institute of Technology

  31. Assembly Plans • Fully documented test rig assembly plan including: • Process steps referencing part numbers • Torque specifications • Notes on special care items to avoid damage to equipment Rochester Institute of Technology

  32. Test Plans Rochester Institute of Technology

  33. Questions Rochester Institute of Technology

  34. BACK-UP Slides Rochester Institute of Technology

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