P14453

1. P14453 Dresser-Rand Compressor Bearing Dynamic Similarity Tester

2. Agenda • Team Introduction • Background – Steve Lucchesi • Problem Statement – Steve Kaiser • Deliverables – Josh Plumeau • Stakeholders – Luke Trapani • Engineering Requirements – Shawn Avery • Benchmarking – Shawn Avery • Milestones Timeline – Luke Trapani • Issues – Josh Plumeau

3. Introduction/Roles

4. Project Background • 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.

5. What is a Journal Bearing? • Journal, or plain bearings, consist of a shaft or journal which rotates freely in a supporting sleeve with lubricant film to provide a low friction surface • A floating ring journal bearing is similar, but consists of an additional component (the ring) that floats in the lubricant between the journal and the sleeve, creating two lubricant layers

6. Past Projects • P09452: Installed Dresser-Rand ESH-1 reciprocating compressor • P12453: Installed a range of sensors on the compressor and expanded the capabilities of the data acquisition (DAQ) system • P13453: Dresser-Rand Compressor Wireless Instrumentation. Monitored health of main crank bearing on the reciprocation compressor • P13505: Designed roller bearing failure test stand. • Markus Holzenkamp’s Thesis

7. Problem Statement • Current State • Bearing monitoring is currently performed on the compressor itself • No current test rig exists on site at RIT • Desired State • Two system level design proposals; one full scale model and one scaled down version • Working concept to remain on site at RIT to allow for further research and development • Project Goals • Allows for quick change-over • Control and measure the following: • Shaft speed • Dynamic/Variable Load Profiles • Oil Temperature and Pressure • Gap measurement between journal and sleeve • Constraints • Budget of $5,000 • Understanding of floating journal ring bearings

8. Project Deliverables • Two system design proposals by SLDR • A full scale design replicating the ESH-1 compressor • A small scale rig that will give useful data while saving space and controlling project costs • Detailed design of selected proposal by DDR • A functional test rig capable of dynamically loading a journal bearing in two axes • Test rig must be small enough to install at RIT • The oiling system must replicate that of the Dresser-Rand ESH-1 compressor

9. Project Deliverables • Data collection system • Measurement of gap between journal and sleeve • Measurement of vibration experienced by bearing • Monitoring of oil temperature, pressure, and flow rate during tests • Condition monitoring must interface with existing DAQ • Test data proving functionality of equipment • Additional desired features • Quick bearing replacement • Low cost to operate and maintain

10. Stakeholders RIT: Researchers: • RIT: Industry Engineers: • Dresser-Rand: • Industries pertaining to the use and/or manufacturing of journal bearings. • 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 ?

11. Engineering Requirements *link to House of Quality upon request: https://edge.rit.edu/edge/P14453/public/Problem%20Definition

12. Benchmarking • Qualitative benchmarking of other bearing test rigs • Speed Range • Load Capabilities • Load application method • Bearing type • Sub-system Benchmarking • Pump • Load application equipment • Motor • Sensors • User Interface NASA Ghent U. LBTR

13. MSD I Milestones Timeline

14. MSD I Milestones Timeline • 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 [10/24/13]: • Subsystem design completed • Meet with guides/panels/stakeholders • Detailed Design & Component Selection [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

15. Issues • Component understanding of journal bearings • Limited experience with bearing analysis • Control systems • The team has limited electrical and controls experience • Complex load control system required • Incorporating current data acquisition system • Availability of required equipment • Drive and loading system will require higher-end equipment that may not be readily available