P14453

Dresser-Rand Compressor Bearing Dynamic Similarity

Tester

AgendaTeam IntroductionBackground – Steve LucchesiProblem Statement – Steve KaiserDeliverables – Josh PlumeauStakeholders – Luke TrapaniEngineering Requirements – Shawn AveryBenchmarking – Shawn AveryMilestones Timeline – Luke TrapaniIssues – Josh Plumeau

Introduction/RolesTeam Member Major Role

Steve Lucchesi Mechanical Engineering Project Manager

Shawn Avery Mechanical Engineering Team Facilitator

Steve Kaiser Mechanical Engineering Project Engineer

Josh Plumeau Mechanical Engineering Project Engineer

Luke Trapani Mechanical Engineering Project Engineer

Project BackgroundObjective:

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.

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

Past ProjectsP09452: Installed Dresser-Rand ESH-1 reciprocating

compressorP12453: Installed a range of sensors on the compressor and

expanded the capabilities of the data acquisition (DAQ) systemP13453: 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

Problem StatementCurrent 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

Project DeliverablesTwo system design proposals by SLDR

A full scale design replicating the ESH-1 compressorA small scale rig that will give useful data while saving space and

controlling project costs

Detailed design of selected proposal by DDRA functional test rig capable of dynamically loading a

journal bearing in two axesTest rig must be small enough to install at RITThe oiling system must replicate that of the Dresser-Rand ESH-1

compressor

Project DeliverablesData collection system

Measurement of gap between journal and sleeveMeasurement of vibration experienced by bearingMonitoring of oil temperature, pressure, and flow rate during testsCondition monitoring must interface with existing DAQ

Test data proving functionality of equipmentAdditional desired features

Quick bearing replacementLow cost to operate and maintain

StakeholdersRIT:

Researchers: RIT:

Industry Engineers: Dresser-Rand:

Industries pertaining to the use and/or manufacturing of journal bearings.

• 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)

Engineering Requirements

Function Engr. Requirement (metric) Unit of Measure Marginal Value Ideal Value

Read/Select Load Profile Yes/No, Time Min. 2 1

Control Shaft Speed Measurement Range, Accuracy rpm 0 to 400, ±30 0 to 2000, ±20

Control Load Measurement Range, Accuracy Lbf TBD 0 to 900, ±10

Control Oil Pressure Measurement Range, Accuracy Psi TBD TBD

Measure Shaft Speed Measurement Range, Accuracy rpm 0 to 400, ±30 0 to 2000, ±20

Measure Load Measurement Range, Accuracy Lbf TBD 0 to 900, ±10

Measure Oil Pressure at Bearing Inlet/Outlet Measurement Range, Accuracy Psi TBD TBD

Measure Oil Temp. Measurement Range, Accuracy ᵒF TBD TBD

Measure Bearing Vibration (Frequency & Amplitude) Measurement Range, Accuracy Hz, in. TBD TBD

Meaure Journal to Sleeve Clearance Measurement Range, Accuracy in. TBD TBD

Measures Oil Flow Rate In/Out Measurement Range, Accuracy in3/s TBD TBD

Measure Torque Transmitted in the Fluid Film Measurement Range, Accuracy lbf-in TBD TBD

Display Shaft Speed Refresh Rate Hz. 0.5 1

Display Load Refresh Rate Hz. 0.5 1

Display Oil Pressure Refresh Rate Hz. 0.5 1

Display Oil Temperature Refresh Rate Hz. 0.5 1

Display Bearing Vibration Refresh Rate Hz. 0.5 1

Display Journal to Sleeve Clearance Refresh Rate Hz. 0.5 1

Provide Component Power Voltage Range V N/A 110 to 240

Record/Save Data Delay Time Sec. 5 2

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

BenchmarkingQualitative 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

MSD I Milestones Timeline

Week 1 Week 2 Week 3 Week 4 Week 1 Week 2 Week 3 Week 4 Week 5 Week 1 Week 2 Week 3 Week 4September October November

Problem Definition

System Design

Sub-System Design

Detailed Design & Component Selection

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

IssuesComponent understanding of journal bearings

Limited experience with bearing analysisControl systems

The team has limited electrical and controls experienceComplex load control system requiredIncorporating current data acquisition system

Availability of required equipmentDrive and loading system will require higher-end equipment

that may not be readily available