Detailed Design Review P14453: Dresser-Rand Compressor Bearing Dynamic Similarity Test Rig Detailed Design Review December 10, 2013 Rochester Institute of Technology

Project Team Team Member Major Role Steve Lucchesi Mechanical Engineering Project Manager Shawn Avery Team Facilitator Steve Kaiser Project Engineer Josh Plumeau Luke Trapani Steve L December 10, 2013 Rochester Institute of Technology

Rochester Institute of Technology Stakeholders RIT: Researchers: Industry Engineers: Dresser-Rand: MSD1 Team – 14453 Graduate/Masters Students William Nowak (Xerox) Dr. Jason Kolodziej Dr. Stephen Boedo Assistant Professor Associate Professor (Primary Customer) (Subject Matter Expert) Steve L ? James Sorokes Scott Delmotte Principal Engineer Mgr. Project Engineering Financial Support Point of Contact December 10, 2013 Rochester Institute of Technology

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 Steve L December 10, 2013 Rochester Institute of Technology

Rochester Institute of Technology 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. Steve L October 5, 2013 Rochester Institute of Technology

Rochester Institute of Technology Customer Needs Steve L Importance is on a 1,3,9 scale. All ones have been omitted for this presentation. December 10, 2013 Rochester Institute of Technology

Engineering Requirements Steve L December 10, 2013 Rochester Institute of Technology

Rochester Institute of Technology Pareto Analysis Steve L *link to House of Quality upon request: https://edge.rit.edu/edge/P14453/public/Problem%20Definition December 10, 2013 Rochester Institute of Technology

Functional Decomposition Steve K December 10, 2013 Rochester Institute of Technology

Rochester Institute of Technology System Architecture Steve December 10, 2013 Rochester Institute of Technology

Rochester Institute of Technology Top Level Layout Steve December 10, 2013 Rochester Institute of Technology

Rochester Institute of Technology Top Level Layout Steve December 10, 2013 Rochester Institute of Technology

Load Application Selection Summary Steve December 10, 2013 Rochester Institute of Technology

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 Steve December 10, 2013 Rochester Institute of Technology

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) Steve December 10, 2013 Rochester Institute of Technology

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 Steve December 10, 2013 Rochester Institute of Technology

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 Steve December 10, 2013 Rochester Institute of Technology

Pneumatic Actuation Design High load analysis (6” bore actuator)   𝑀𝑎𝑥 𝑓𝑜𝑟𝑐𝑒=1900 𝑙𝑏𝑠 𝑃𝑖𝑠𝑡𝑜𝑛 𝐴𝑟𝑒𝑎= 𝜋 𝐷 2 4 = 𝜋 6 2 4 =28.274𝑖 𝑛 2 𝐴𝑖𝑟 𝑝𝑟𝑒𝑠𝑠𝑢𝑟𝑒= 𝐹 𝐴 = 1900 28.274 =67.2𝑝𝑠𝑖 Low load analysis (3.25” bore Actuator) 𝑀𝑎𝑥 𝑓𝑜𝑟𝑐𝑒=600 𝑙𝑏𝑠 𝑃𝑖𝑠𝑡𝑜𝑛 𝐴𝑟𝑒𝑎= 𝜋 𝐷 2 4 = 𝜋 3.25 2 4 =8.3𝑖 𝑛 2 𝐴𝑖𝑟 𝑝𝑟𝑒𝑠𝑠𝑢𝑟𝑒= 𝐹 𝐴 = 600 8.3 =72.3𝑝𝑠𝑖 Steve December 10, 2013 Rochester Institute of Technology

Rochester Institute of Technology 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 Steve December 10, 2013 Rochester Institute of Technology

Rochester Institute of Technology 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 Steve December 10, 2013 Rochester Institute of Technology

Rochester Institute of Technology 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 Steve December 10, 2013 Rochester Institute of Technology

Rochester Institute of Technology 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 Steve December 10, 2013 Rochester Institute of Technology

Structural Support System Component list: Table Base Table Horizontal Cylinder Mount Vertical Cylinder Risers (2) Shaft Couplings Motor Vibration Mat Bearing Risers Steve December 10, 2013 Rochester Institute of Technology

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 Steve December 10, 2013 Rochester Institute of Technology

Rochester Institute of Technology Drive System Component list: Leeson DC Motor R+W Bellows Type Shaft Coupling Shaft SealMaster Pillow Block Roller Bearings Steve December 10, 2013 Rochester Institute of Technology

Rochester Institute of Technology 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 Steve December 10, 2013 Rochester Institute of Technology

Rochester Institute of Technology User Interface Steve December 10, 2013 Rochester Institute of Technology

Rochester Institute of Technology Bill of Materials Steve December 10, 2013 Rochester Institute of Technology

Rochester Institute of Technology Risk Assessment Steve December 10, 2013 Rochester Institute of Technology

Rochester Institute of Technology 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 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 Steve December 10, 2013 Rochester Institute of Technology

Rochester Institute of Technology 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 Steve December 10, 2013 Rochester Institute of Technology

Rochester Institute of Technology Test Plans Steve December 10, 2013 Rochester Institute of Technology

Rochester Institute of Technology Questions Steve December 10, 2013 Rochester Institute of Technology

Rochester Institute of Technology BACK-UP Slides Steve December 10, 2013 Rochester Institute of Technology