P14453: Dresser-Rand Compressor Bearing Dynamic Similarity Test Rig Subsystem Design Review

Rochester Institute of Technology 1

P14453: Dresser-Rand Compressor Bearing Dynamic Similarity Test Rig

Subsystem Design Review

October 29, 2013

Rochester Institute of Technology

Project Team

October 29, 2013 2

Team Member Major Role

Steve Lucchesi Mechanical Engineering Project Manager

Shawn Avery Mechanical Engineering Good Vibrations

Steve Kaiser Mechanical Engineering Project Engineer

Josh Plumeau Mechanical Engineering Project Engineer

Luke Trapani Mechanical Engineering Project Engineer


Stakeholders

October 29, 2013 3

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)


Subsystem Design Review Agenda

October 29, 2013 4

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)


Objective Statement

October 29, 2013 5

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.


Functional Decomposition Review

October 29, 2013 6


Functional Decomposition:Running the Test

October 29, 2013 7


P14453 System Design Summary

October 29, 2013 8

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 Function Component SelectionRotate Journal DC Motor

Apply Load to Bearing EHA(s)

Drive Line Direct

Pressurize Oil Diaphragm Pump

Direct Oil To Bearing Sleeve Side

Monitor Film Thickness Proximity Sensor

Monitor Vibration Accelerometer

Monitor Torque Motor Load Feedback

Monitor Oil Temp Thermocouple

Provide Power Wall OutletInstall Bearing 2 Piece Housing

Install Shaft Chuck

Support Shaft Roller Bearings


P14453 System Design Summary

October 29, 2013 9

Oil Sump

Support Bearings

Hydraulic Cylinders

Bearing Shaft

Test Bearing

Drive Motor

Shaft Coupling

Test Stand

Load Block / Custom Bearing Housing


System Architecture

October 29, 2013 10


Critical Subsystem Identification

October 29, 2013 11


Design/Analysis Plan

October 29, 2013 12


Journal Bearing Analysis

October 29, 2013 13

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.



October 29, 2013 14

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.



October 29, 2013 15

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.



October 29, 2013 16

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



October 29, 2013 17

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


Load Application Analysis:Hydraulic Cylinders

October 29, 2013 18

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)



October 29, 2013 19

Parker Electro-Hydraulic Actuator (EHA) Hybrid combining benefits of hydraulic cylinder and electric servo Self-contained unit Speed and Load Range Size



October 29, 2013 20

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



October 29, 2013 21

0 50 100 150 200 250 300 350 400-8000

-6000

-4000

-2000

0

2000

4000

6000

8000

10000

Load History for Main Crank Bearing

Force XForce Y

Crank Angle (degrees)

Forc

e (N

)



October 29, 2013 22

Shaft Operating RPM 360RPMShaft Cycle Time 0.1667sShaft Frequency 6HzEHA Piston Velocity 1.8 in/sEHA Piston Displacement 0.01 inEHA Displacement Time 0.0056sEHA Cycle Time 0.0111sEHA Frequency 90HzEHA X-Direction Force Cycles 2cycles/rotationEHA X-Direction Force Frequency 12HzEHA Y-Direction Force Cycles 4cycles/rotationEHA Y-Direction Force Frequency 24Hz

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)?){$$$}


Lubrication System analysis:

October 29, 2013 23

Oil PressureAdjustable from 10 – 25 psiMeasure 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 pumpOil and chemical resistant plumbingSeparate path with/without oil filter

Journal Housing

Oil reservoirOil pumpOil filter

Oil pressure transducer

Path branches



October 29, 2013 24

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.

( 𝑃1

⍴1+𝑉 1

2

2+𝑔𝑧 1)−( 𝑃2

⍴2+𝑉 2

2

2+𝑔 𝑧2)=h𝑙𝑡

( 𝑃1

1.77+ 0.01722

2+0)−( 25

1 .77+ 0 .01722

2+32.17∗4)=h 𝑙𝑡

( 𝑃1

1.77 )−( 2 51 .77

+128.68)=34.50 0.01722

2

𝑃1=26.58 𝑝𝑠𝑖



October 29, 2013 25

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.

0 10 20 300

0.51

1.52

2.53 Flow (GPM) vs. Pressure

Pressure (Psi)

Flow

Rat

e (G

PM)

PERFORMANCE @ 12V DCPRESSURE FLOW CURRENT

PSI GPM AMPS0 13 0.9

10 0.7320 0.6230 0.49

4



October 29, 2013 26

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 S

yste

m

Nominal PressurePump-side PressureSystem-side Pressure



October 29, 2013 27

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


Structural Analysis

October 29, 2013 28

Initial calculations on were done on the following:

• Reaction forces on the support bearings

• Support bearing life rating

• Support bearing load rating


Structural Analysis

October 29, 2013 29

Support Bearings (Cylindrical roller bearing)• Maximum size = 2.75• Basic Dynamic Load Rating = 11,000 lbf = 48930 N• Limiting Speed = 360 rpm


Structural Analysis

October 29, 2013 30


Control System Schematic

October 29, 2013 31


Control System Simulation

October 29, 2013 32


Updated Risk Assessment

October 29, 2013 33


MSD1 Milestones Chart

October 29, 2013 34

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


MSD1 Milestones

October 29, 2013 35

• 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 Selection Kick-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


MSD1 Detailed Design Milestones

October 29, 2013 36

• 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 build

phase– 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


Questions?

October 29, 2013 37


BACK-UP SLIDES

October 10, 2013 38


Customer Needs

October 5, 2013 39

Objective Number Customer Objective Description ImportanceCN 1.1 Measures Shaft Speed 9CN 1.2 Measures Load 9CN 1.4 Measures Bearing Dynamics 9CN 1.7 Measures Vibration 9CN 1.8 Measure Gap Between Journal & Sleeve 3CN 1.9 Measures Oil Flow Rate In/Out 3

CN 1.11 Measure Oil Pressure at Points in the Bearing 3CN 2.1 Controls shaft speed 9CN 2.2 Allows for variable load profile 9CN 2.3 Allows for dynamic load profile 3CN 2.4 Controls oil pressure 9CN 2.5 Able to isolate bearing vibration from machine vibration 3CN 3.1 Displays acquired data 3CN 3.2 Allows for Input of test parameters 9CN 3.3 Records test data 9CN 4.1 Test rig has a small footprint 3CN 4.2 Quick bearing replacement 9CN 4.3 Simple oil replacement 3CN 5.1 Bearing Oiling System is contained 9CN 5.2 Guarded Rotating Assembly 9CN 5.3 Hot Surfaces are to be insulated 9CN 6.1 Fits within budget 3CN 6.2 Low cost repairs 3CN 6.3 Low cost replacement 3CN 6.4 Low maintenance 3CN 7.1 Compatible with existing DAQ equipment 9CN 7.2 Minimum of 2 system sensors 3CN 7.3 Variable bearing size/design accomodations 3CN 7.4 Allows for replication of current ESH-1 compressor oiling system 3


Engineering Requirements

October 5, 2013 40

Req. # Importance CN Source Function Engr. Requirement (metric) Unit of MeasureER 1 9 4.2 Read/Select Load Profile Yes/No, Time Min.ER 2 9 2.1 Control Shaft Speed Measurement Range, Accuracy rpmER 3 9 2.2, 2.3 Control Load Measurement Range, Accuracy LbfER 4 9 2.4 Control Oil Pressure Measurement Range, Accuracy PsiER 5 9 1.1 Measure Shaft Speed Measurement Range, Accuracy rpmER 6 9 1.2 Measure Load Measurement Range, Accuracy LbfER 7 3 1.6 Measure Oil Pressure at Bearing Inlet/Outlet Measurement Range, Accuracy PsiER 9 9 1.7 Measure Bearing Vibration (Frequency & Amplitude) Measurement Range, Accuracy Hz, in.ER 10 3 1.8 Meaure Journal to Sleeve Clearance Measurement Range, Accuracy in.ER 11 3 1.9 Measures Oil Flow Rate In/Out Measurement Range, Accuracy in3/sER 12 3 1.10 Measure Torque Transmitted in the Fluid Film Measurement Range, Accuracy lbf-inER 14 3 1.12 Measure Speed of the Floating Ring Measurement Range, Accuracy rpmER 16 9 1.1, 2.1, 4.1 Display Shaft Speed Refresh Rate Hz.ER 17 9 1.2, 2.2, 2.3, 4.1 Display Load Refresh Rate Hz.ER 20 9 1.7, 2.5, 4.1 Display Bearing Vibration Refresh Rate Hz.ER 21 9 1.7, 4.1 Display Journal to Sleeve Clearance Refresh Rate Hz.ER 22 3 5.2 Replace Bearings Time Min.ER 23 3 5.2 Replace Shaft Time Min.ER 24 3 5.3 Replace Oil Time Min.ER 25 9 Implied Provide Component Power Voltage Range VER 26 9 4.3 Record/Save Data Delay Time Sec.ER 27 3 7.3 Vary Test Specimen Size Measurement Range In


Pareto Analysis

October 5, 2013 41

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

https://edge.rit.edu/edge/P14453/public/Problem%20Definition

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P14453: Dresser-Rand Compressor Bearing Dynamic Similarity Test Rig Subsystem Design Review

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