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

2. 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

3. 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

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
Steve L
December 10, 2013
Rochester Institute of Technology

5. 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

6. 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

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

8. Rochester Institute of Technology
Pareto Analysis
Steve L
*link to House of Quality upon request:
December 10, 2013
Rochester Institute of Technology

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

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

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

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

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

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

19. 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

20. 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

21. 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

22. 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

23. 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

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
Steve
December 10, 2013
Rochester Institute of Technology

25. 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

26. 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

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

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

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

30. 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

31. 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

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

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

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