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

Rochester Institute of Technology 1

P14453: Dresser-Rand Compressor Bearing Dynamic Similarity Test Rig

System Design Review

October 5, 2013

Rochester Institute of Technology

Project Team

October 5, 2013 2

Team 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


Stakeholders

October 5, 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)


System Design Review Agenda

October 5, 2013 4

Objective Statement Review of Customer Needs Review of Engineering Requirements System Analysis:

Pareto Analysis Functional Decomposition

System Architecture Concept Selection

Morphological Chart Pugh Charts

Engineering Analysis & Feasibility Risk Assessment Milestones Chart (Updated)


Objective Statement

October 5, 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.


Customer Needs

October 5, 2013 6

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 7

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 8

*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


Functional Decomposition

October 5, 2013 9


Functional Decomposition:Test Setup

October 5, 2013 10


Functional Decomposition:Running the Test

October 5, 2013 11


Functional Decomposition:Monitoring Bearing Characteristics

October 5, 2013 12


System Architecture

October 5, 2013 13

Concept Selection:System Morphological Chart

October 5, 2013 Rochester Institute of Technology 14

System Function A B C D

Rotate Journal

Electric Motor Turbine Magnetic Field Gasoline Engine

Apply Load to Bearing

Pneumatics Cams Springs Hydraulics

Pressurize Oil

Piston Pump Gerotor Pump Peristaltic Pump Centrifugal Pump

Direct Oil To Bearing

Shaft Side Supply

Sleeve Side Supply Oil Ring (Lap)

Pressurized Side Entry

Monitor Gap Between

Journal and Bearing

Proximity Sensor Resistance Sensor Capacitance Sensor Ultrasonic

Monitor Vibration

Accelerometer Proximity Sensor Piezo Electric Device

(Intentionally Left Blank)

System Function A B C D

Monitor Torque

Torque Sensor Motor Load Feedback Strain Gauge


Monitor Oil Temp

Thermometer Thermocouple Infrared Sensor


Provide Power

Wall Outlet Generator Solar Power Nuclear Power

Install Bearing

2 Piece Housing Press into 1 Piece Housing

Collet


Install Shaft

Clamp Flange Collet Quick-Connect

Support Shaft

Journal Bearings Roller Ball Bearings Tapered Roller Bearings Air Bearings


Concept Selection:Concept Summary

October 5, 2013 15

System Function Datum (PG II 1L) Concept A Concept B Concept CRotate Journal Electric Motor Electric Motor Gasoline Engine Electric MotorApply Load to

BearingHydraulics Hydraulics Cams Pneumatics

Pressurize Oil Gerotor Pump Gerotor PumpCentrifugal

PumpPiston Pump

Direct Oil To Bearing

Sleeve Slide Supply

Shaft Side Supply

Oil Ring (lap)Sleeve Slide

Supply

Monitor Gap Between Journal

and BearingN/A Proximity Sensor

Capacitance Sensor

Resistance Sensor

Monitor Vibration

N/A AccelerometerPiezoelectric

DeviceAccelerometer

Monitor Torque Torque Sensor Torque Sensor Strain Gauge Torque SensorMonitor Oil

TempThermocouple Thermocouple Thermometer Thermocouple

Provide Power Wall Outlet Wall Outlet Generator Wall Outlet

Install Bearing 2 Piece Housing 2 Piece HousingPress into 1

Piece2 Piece Housing

Install Shaft Quick-Connect Quick-Connect Flange Quick-Connect

Support Shaft Journal BearingsTapered Roller

BearingsRoller Ball Bearings

Tapered Roller Bearings


Concept Selection:System Pugh Analysis

October 5, 2013 16

ConceptSelection Criteria Datum A B C

1 Skills Required to Create Design

D A T U M

- - -2 Skills Required to Build the Design - - -3 Ease of Build - - -4 Ease of Programming 0 + 05 Material and Component Cost - + -6 Feasibility for 2 Semester Completion - - -7 Ease of Test Setup and Maintenance 0 - 08 Repeatability, Accuracy, and Precision + - +9 Intuitive to Use 0 - 0

10 Machine Asthetics + + +11 Safety + - +12 Load Range + + +13 Speed Range 0 - 014 Life Expectancy 0 - 015 Range of Possible Test Bearing Sizes + + +16 Allows Two Axis Loading + + +16 Collects Desired Data + + +

Sum of +'s 0 7 7 7Sum of 0's 0 5 0 5Sum of -'s 0 5 10 5

Totals 0 2 -3 2


Concept Selection:Drivetrain Pugh Analysis

October 5, 2013 17

Concept - DIRECT DRIVE DATUM Concept - VEE Belt Datum

Selection Criteria Direct Drive Gear Chain COG Belt VEE Belt Flat Belt CVT Direct Drive Gear Chain COG Belt VEE Belt Flat Belt CVT

1 Skills Required to Create Design

D A T U M

- - - - - - + - - -

D A T U M

+ -

2 Skills Required to Build the Design 0 - - + + - 0 - + - + -

3 Ease of Build 0 - - - - - + 0 0 0 0 -

4 Ease of Programming 0 0 0 - - - + + + + - -

5 Material and Component Cost - + - 0 - - 0 - + - - -

6 Ease of Test Setup and Maintenance 0 - - - - 0 + + 0 0 0 +

7 Repeatability, Accuracy, and Precision 0 0 0 - - - + + + + - 0

8 Intuitive to Use 0 - - - - 0 + + 0 0 0 +

9 Machine Asthetics + + + + + + - 0 0 0 0 +

10 Safety 0 - - - - 0 + 0 0 0 0 +

11 Load Range + + + + - + - + + + 0 0

12 Speed Range 0 0 0 0 0 0 0 0 0 0 0 0

13 System Vibration - - - 0 0 0 + - - - + 0

14 System Shock - - 0 + + + - - - - + 0

15 Life Expectancy 0 - - - - - + + + + - -

Sum of +'s 0 2 3 2 4 3 3 9 6 6 4 0 4 4

Sum of 0's 0 9 3 4 3 2 5 3 4 6 6 0 7 5

Sum of -'s 0 4 9 9 8 10 7 3 5 3 5 0 4 6

Total 0 -2 -6 -7 -4 -7 -4 6 1 3 -1 0 0 -2


Drivetrain Analysis:Direct Drive

October 5, 2013 18

Direct Drive

- Direct drive is done by attaching the motor straight to the shaft that is going to be spun.



October 5, 2013 19

Direct Drive

- This can be done by using a coupling to attach two or bolting the two pieces together using a flange. The problem with both ideas is that without a dampening device on the motor or on the coupling the shaft could see outside vibrations which could affect testing results.

- Shaft alignment is also crucial in making sure that no extraneous forces are acting on the shafting while it is rotating which could cause the system to fail.



October 5, 2013 20

Direct Drive


Drivetrain Analysis:Belt Drives

October 5, 2013 21

Belt Drives Research shows that generally different drive types can be organized into a

linear range due to their properties, below is the range created as a result of the research:

Driveline stiffness: Stiff Soft

Low HighMisalignment allowance:

Low HighShock absorption:

High LowSystem vibration:



October 5, 2013 22

Types of Belt Drives

Flat belts – Used for high speed applications, used because belt slips before component damage occurs in overload scenarios.

Vee belts – Used for mid range to high speed applications, industry standard due to it’s vibration absorbing properties, allowance for misalignment, and limited slippage (~15%) due to the sloped contact surfaces.

Timing belts – Used for mid range to high speed applications, used in applications where very accurate position and speed correlation is needed. Less vibration absorption and misalignment tolerances than other belt types and the most expensive belt drive. Broken down into three types (specified later).



October 5, 2013 23

Vee Belts:Benefits:

Drawbacks:• Belt slip – Vee belts have both built in slip and system slip, this is based on both speed and environmental

factors. This complicates the speed control system in the rig.• Expense – Like most indirect drives there are multiple precision parts required. This raises expense and

system complication. • Maintenance – Continuous belt systems have the drawback that they must have an open side In the system

for the removal, replacement, and maintenance of the belt. However this can be a benefit due to the system being designed for easy access.

• Lubrication sensitivity – Vee belt drives are extremely sensitive to lubricants. When lubrication and other debris are introduced to the system the friction and slippage characteristics of the drive can vary greatly.

• Smooth startup – Operates smoothly at a large range of speeds and torques.• Long operation life – Well designed and maintained vee belt drives can have service live from 8,000 –

12,000 hours.• High efficiency – Vee belt drives can have efficiencies of 90-96%.• Vibration absorption – Built in belt slip, elastic properties of belt, and consistent engagement mean that

driveline absorbs shocks and vibrations .• Large power and speed range – Vee belt drives can be used in a wide range of speeds and power ratings,

the Journal Bearing test range is covered in this range.



October 5, 2013 24

Cogged Belts:Benefits:

Drawbacks:

• Smooth startup – Operates smoothly at a large range of speeds and torques.• Long operation life – Well designed and maintained cogged belt drives can have service live from 8,000 –

12,000 hours.• High efficiency – High efficiency, more-so than vee belts, 94-98% efficient.• Positional accuracy – Cogged belt design means high positional accuracy, in machines such as spot welding

machines the positional accuracy of the belt is normally less than 1 mm.• Large power and speed range – Cogged pulleys can handle a large range of speeds and power ratings

(1000KW for HTD and 600KW for GTD)• Lubrication Sensitivity – Because of the cogs on the belt there is no danger of slip caused by lubricants

and other materials.

• Expense – Like most indirect drives there are multiple precision parts required. This raises expense and system complication Additionally cogged drives are more expensive relative to other belt systems.

• Maintenance – Continuous belt systems have the drawback that they must have an open side In the system for the removal, replacement, and maintenance of the belt. However this can be a benefit due to the system being designed for easy access.

• Low misalignment tolerance – Because cogged belts are stiffer than other belt types some of the benefits of a flexible belt are lost as is the case for misalignment. A cogged belt’s tolerance for misalignment can be as low as 10% that of an equivalent vee belt.



October 5, 2013 25

Example Vee Belt calculation:

Assuming a speed ratio of 2:1 with a output of 4000rpm the belt required would be (Bando USA):

1 std. A transmission beltpulley 1: 10.40 in OD pulley 2: 5.20 in OD


Concept Selection:Load Application Pugh Analysis

October 5, 2013 26

Concept - HYDRAULIC CYLINDER DATUM Concept - PNEUMATIC CYLINDER DATUM

Selection Criteria Pneumatic Cylinder Hydraulic Cylinder Electric Servo Mechanical (Cam)

Pneumatic Cylinder Hydraulic Cylinder Electric Servo Mechanical (Cam)

1 Frequency at Load -

D A T U M

+ +

D A T U M

+ + +

2 Load Accuracy - + -

+ + -

3 Engineering Analysis - 0 -

+ + -

4 Cost + - 0

- - -

5 Input Power 0 0 +

0 0 +

6 Controls - 0 +

+ + +

7 Size 0 - -

0 - -

8 Safety + + -

- + -

9 Durability 0 - -

0 - -

10 Required Maintenance + 0 -

- - -

Sum of +'s 3 0 3 3

0 4 5 3

Sum of 0's 3 0 4 1

0 3 1 0

Sum of -'s 4 0 3 6

0 3 4 7

Total Score -1 0 0 -3

0 1 1 -4


Load Application Analysis:Hydraulic Cylinders

October 5, 2013 27

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 5, 2013 28

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



October 5, 2013 29

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 ≈ 2.9in/s Cycle time:

(0.01in)/(2.8 in/s)*2(extend & retract)=0.007143 secs/cycle

Actuator Frequency:1/(0.007143 secs/cycle)=

140 cycles/second = 140Hz Compresser Frequency:

360rpm/60=6rps(rotation=cycle) = 6Hz Requested Frequency:

2000rpm/60 = 33.3Hz


Load Application Analysis:Pneumatic Cylinders

October 5, 2013 30

Pneumatic Load Application: Benefits

Pneumatic cylinders are relatively inexpensive Compressed air is readily available within most lab spaces

Disadvantages Nonlinear operation, specifically when direction of motion changes Overcoming resulting issues creates a complicated controls problem

Below is a diagram for a twin servo valve control setup for a pneumatic cylinder as proposed by J. Falcao Carneiro, F. Gomes de Almeida in their paper Using two servo-valves to improve pneumatic force control in industrial cylinders.



October 5, 2013 31

The following graph, from their paper, demonstrates the issues related to pneumatic load control.

This problem is accentuated by the fact that we will require high loads ( ~ -3000 to 4000 N ) at very low displacement ( Less than 0.5 mm ).

Forc

e (N

)

Velocity (m/s)



October 5, 2013 32

Control System for Pneumatic Loading Requires two servo valves per cylinder System needs to react in advance in order to redirect air in

time to maintain proper shaft loading Controls programming will be time intensive

Hydraulic systems do not suffer from issues with compressibility, and therefore react better to high frequency, low displacement changes


Additional Engineering Analysis

October 5, 2013 33

Structural: Shaft stress & deformations Mounting component stress Support bearing analysis

Lubrication System: Required pressure analysis Flow rate

Data Acquisition System: Sampling rate

Power Requirements


Proposed Layout 1: Direct Drive

October 5, 2013 34

Oil Sump

Support Bearings

Hydraulic Cylinders

Bearing Shaft

Test Bearing

Drive Motor

Shaft Coupling

Test Stand

Load Block / Custom Bearing Housing


Proposed Layout 2: Belt Drive

October 5, 2013 35

Support Bearings

Bearing Shaft

Belt System

Hydraulic Cylinders

Oil Sump

Test Bearing

Test Stand

Drive Motor

Load Block / Custom Bearing Housing


Risk Assessment

October 5, 2013 36

Risk Item Effect Cause Likelihood Severity Importance Action to Minimize

Will not measure No usable dataSensor failure or disconnect,

improper shaft setup, too much outside noise, DAQ mal-function

3 9 27Locking electrical

connections, System isolated from

environmental effects

Rotating element hazard

Operator hazard/death

No guard, guard damage, improper maintenance, improper design, exposed shaft, exposed rotating

components3 9 27

Proper design of guarding for all rotating elements (i.e.

belts, shaft)

Will not output data No data

Sensor malfunction, DAQ disconnect, DAQ malfunction,

power failure3 9 27 Proper selection of durable

sensor equipment

Improper/no shaft loading

No useful data, test rig

destruction

Operator error, input error, poor connection, load applicator

malfunction3 9 27 Proper training procedure

development

Lubrication system failure

Damage to test specimen, damage to

system

Loss of pump power, leak in structure, obstruction in flow 3 9 27

Active oil pressure monitoring, Lubricant

filtration system utilized


MSD1 Milestones Chart

October 5, 2013 37

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 5, 2013 38

• 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


MSD1 Sub-System Design Milestones

October 5, 2013 39

• Develop sub-sys and interfaces [10/8/13]:– Consider alternatives, feasibility, requirement flow-

down– Refine requirements, needs vs. spec mapping– Perform next level functional decomposition– Perform next level of risk assessment

• Second-order Analysis (PoC) [10/17/13]:– Manual formulation/analysis – CAD modeling– FEA analysis/simulations– Review feasibility– Develop/update test plan

• Prepare presentation (PoC, pre-DDR) [10/22/13]:

– Action items from sub-system design and impact on project

– Compile modeling/FEA– Review and analysis of function flow-down within sub-

systems– Feasibility demonstrated by PoC– What is the requirement test schedule

– Has the design been adequately reviewed?


Questions?

October 5, 2013 40

Documents

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