1. P14453: Dresser-Rand Compressor Bearing Dynamic Similarity Test Rig Subsystem Design Review October 29, 2013Rochester Institute of Technology1

2. Project Team October 29, 2013Rochester Institute of Technology2 Team MemberMajorRole Steve LucchesiMechanical EngineeringProject Manager Shawn AveryMechanical EngineeringGood Vibrations Steve KaiserMechanical EngineeringProject Engineer Josh PlumeauMechanical EngineeringProject Engineer Luke TrapaniMechanical EngineeringProject Engineer

3. Stakeholders October 29, 2013Rochester Institute of Technology3 RIT:Researchers: RIT: Industry Engineers: Dresser-Rand: 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 MSD1 Team – 14453 Graduate/Masters Students William Nowak (Xerox)

4. Subsystem Design Review Agenda October 29, 2013Rochester Institute of Technology4  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)

5. Objective Statement October 29, 2013Rochester Institute of Technology5  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.

6. Functional Decomposition Review October 29, 2013Rochester Institute of Technology6

7. Functional Decomposition: Running the Test October 29, 2013Rochester Institute of Technology7

8. P14453 System Design Summary October 29, 2013Rochester Institute of Technology8  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 System FunctionComponent Selection Rotate JournalDC Motor Apply Load to BearingEHA(s) Drive LineDirect Pressurize OilDiaphragm Pump Direct Oil To BearingSleeve Side Monitor Film Thickness Proximity Sensor Monitor VibrationAccelerometer Monitor TorqueMotor Load Feedback Monitor Oil TempThermocouple Provide PowerWall Outlet Install Bearing2 Piece Housing Install ShaftChuck Support ShaftRoller Bearings

9. P14453 System Design Summary October 29, 2013Rochester Institute of Technology9 Oil Sump Support Bearings Hydraulic Cylinders Bearing Shaft Test Bearing Drive Motor Shaft Coupling Test Stand Load Block / Custom Bearing Housing

10. System Architecture October 29, 2013Rochester Institute of Technology10

11. Critical Subsystem Identification October 29, 2013Rochester Institute of Technology11

12. Design/Analysis Plan October 29, 2013Rochester Institute of Technology12

13. Journal Bearing Analysis October 29, 2013Rochester Institute of Technology13 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.

14. Journal Bearing Analysis October 29, 2013Rochester Institute of Technology14 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.

15. Journal Bearing Analysis October 29, 2013Rochester Institute of Technology15 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.

16. Journal Bearing Analysis October 29, 2013Rochester Institute of Technology16 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

17. Journal Bearing Analysis October 29, 2013Rochester Institute of Technology17 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

18. Load Application Analysis: Hydraulic Cylinders October 29, 2013Rochester Institute of Technology18  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)

19. Load Application Analysis: Hydraulic Cylinders October 29, 2013Rochester Institute of Technology19  Parker Electro-Hydraulic Actuator (EHA)  Hybrid combining benefits of hydraulic cylinder and electric servo  Self-contained unit  Speed and Load Range  Size

20. Load Application Analysis: Hydraulic Cylinders October 29, 2013Rochester Institute of Technology20  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

21. Load Application Analysis: Hydraulic Cylinders October 29, 2013Rochester Institute of Technology21

22. Load Application Analysis: Hydraulic Cylinders October 29, 2013Rochester Institute of Technology22 Shaft Operating RPM360RPM Shaft Cycle Time0.1667s Shaft Frequency6Hz EHA Piston Velocity1.8in/s EHA Piston Displacement0.01in EHA Displacement Time0.0056s EHA Cycle Time0.0111s EHA Frequency90Hz EHA X-Direction Force Cycles2cycles/rotation EHA X-Direction Force Frequency12Hz EHA Y-Direction Force Cycles4cycles/rotation EHA Y-Direction Force Frequency24Hz 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)?){$$$}

23. Lubrication System analysis: October 29, 2013Rochester Institute of Technology23  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 reservoir Oil pump Oil filter Oil pressure transducer Path branches

24. Lubrication System analysis: October 29, 2013Rochester Institute of Technology24  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.

25. Lubrication System analysis: October 29, 2013Rochester Institute of Technology25  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.

26. Lubrication System analysis: October 29, 2013Rochester Institute of Technology26  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

27. Lubrication System analysis: October 29, 2013Rochester Institute of Technology27  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. OIL FILTER From Pump To Housing

28. Structural Analysis October 29, 2013Rochester Institute of Technology28  Initial calculations on were done on the following: Reaction forces on the support bearings Support bearing life rating Support bearing load rating

29. Structural Analysis October 29, 2013Rochester Institute of Technology29  Support Bearings (Cylindrical roller bearing) Maximum size = 2.75 Basic Dynamic Load Rating = 11,000 lbf = 48930 N Limiting Speed = 360 rpm

30. Structural Analysis October 29, 2013Rochester Institute of Technology30

31. Control System Schematic October 29, 2013Rochester Institute of Technology31

32. Control System Simulation October 29, 2013Rochester Institute of Technology32

33. Updated Risk Assessment October 29, 2013Rochester Institute of Technology33

34. MSD1 Milestones Chart October 29, 2013Rochester Institute of Technology34

35. MSD1 Milestones October 29, 2013Rochester Institute of Technology35 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 SelectionKick-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

36. MSD1 Detailed Design Milestones October 29, 2013Rochester Institute of Technology36 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 buildphase – 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

37. Questions? October 29, 2013Rochester Institute of Technology37

38. BACK-UP SLIDES October 10, 2013Rochester Institute of Technology38

39. Customer Needs October 5, 2013Rochester Institute of Technology39

40. Engineering Requirements October 5, 2013Rochester Institute of Technology40

41. Pareto Analysis October 5, 2013Rochester Institute of Technology41 *link to House of Quality upon request: https://edge.rit.edu/edge/P14453/public/Problem%20Definitionhttps://edge.rit.edu/edge/P14453/public/Problem%20Definition