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

1. P14453: Dresser-Rand Compressor Bearing Dynamic Similarity Test Rig Final Review Rochester Institute of Technology

2. Project Team Rochester Institute of Technology

3. RIT: Researchers: • RIT: Industry Engineers: • Dresser-Rand: Stakeholders • MSDII Team – 14453 • Graduate/Masters Students • William Nowak (Xerox) • 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 ? Rochester Institute of Technology

4. Final Design Review Agenda • MSD I Action Items • Manufacturing • Problem Tracking • Testing • Results • Conclusions Rochester Institute of Technology

5. MSD I Action Items: Lubrication • Customer feedback indicated that more oil would be required than could be supplied by the initial design • A gear pump was chosen for its ability to flow a large quantity of oil at high pressure • Pump is capable of 0-150 psi • 1.5 gpm flow possible at 50 psi • A pressure relief valve was included to protect the system for overpressure • Valve is capable of handling up to 170 psi • Oil seals were incorporated into the test block to contain outgoing oil • All components were strengthened in order to maintain a robust design Rochester Institute of Technology

6. MSD I Action Items: Load System • Due to budgetary constraints our customer requested that we redesign the load system to be single axis-static load • A pivoting lever system was • chosen due to its simplicity • A 10:1 ratio was utilized in • order to fully load the bearing • with only 200 lbs of weights • Loading was done from under the • table to reduce the impact on the • table surface for later development • The design remains robust enough • to adapt to full dynamic loading for • follow-on projects Rochester Institute of Technology

7. MSD I Action Items: Test Bearing Housing • Conversations with our guide determined that the three piece housing would be too complicated to manufacture • A one piece design was implemented • Test bearing became a press fit design • Oil seals were pressed into the block to control oil flow • A single piece eliminated concerns about stack up issues and provided for more accurate readings • A one piece steel part is more durable with no concern about structural failure Rochester Institute of Technology

8. Manufacturing • Table Base • Steel tube stock pre-ordered to length • Cleaning • Welding prep • Welded together in machine shop: THANK YOU ROB! • Painted black • Table Test Surface • Hole profiles water-jetted in machine shop • Water-jetted holes hand tapped • Mated to table base Rochester Institute of Technology

9. Manufacturing • Test Bearing Block • Steel Block milled to size • Surface ground to drawing spec • All bearing hole machining done in lathe: THANK YOU JAN! • Oil feed/return lines, load cell hole, drilled and tapped • Test bearing pressed in • Test Shaft • Machined to size in lathe (THANK YOU ROB!) • Ground to clearance spec Rochester Institute of Technology

10. Manufacturing • Load System • Pivot Pin Mounts • Cut to size, ground to spec • Holes drilled and tapped • Pivot & Load Pins • Lever Arm • Cut to size, ground to spec • Holes drilled and tapped • Weight strap • Lubrication System • Holes drilled and tapped in table base for locating pump motor, gear pump, filter bracket • Hoses cut to size and crimped, various hose couplings • Oil reservoir Rochester Institute of Technology

11. Final Build Photos Rochester Institute of Technology

12. Problem Tracking: • Test Surface machining/finishing: • Table-top was too large to machine without re-indexing • Re-indexing could lead to misalignment • Table-top was machined on the Brinkman Lab water jet • Lubrication System Motor Mount: • Multiple options were available regarding pump motor mounting locations/methods • After a PUGH analysis it was decided to mount the pump to the lower table using the four mounting holes on the motor Rochester Institute of Technology

13. Problem Tracking: • Lubrication Reservoir Weld-up/Assembly: • Welding thin sheet metal with an arc welder is extremely difficult. Being bad at arc welding only makes it worse • The team worked with Rob in the machine shop to properly weld the tank • The tank was completed enough to make it operational • Bearing-Shaft Clearance: • When pressed into the test-block the internal bore diameter of the bearing decreased, causing negative clearance between it and the shaft • The team worked with Rob to measure the bore and adjust the shaft outside diameter to accommodate the change Rochester Institute of Technology

14. Problem Tracking: • Hydraulic Hose Crimping: • The machine shop did not have the proper crimping tools for the hydraulic fittings and most companies would only crimp the fittings of their specific manufacturer • After calling many local businesses “Empire Radiator Service” on Dewey Ave. was the only company that would crimp our generic fittings • Motor/Motor-Controller Overloading: • The total amount of torque required to drive the shaft was greater than the motor was rated for due to calculation discrepancies • After a PUGH analysis it was decided to use a belt drive to decrease the torque load on the motor Rochester Institute of Technology

15. Problem Tracking: • Motor-Controller Overloading: • Constant overloading and an ‘aggressive’ settings setup lead to the first motor controller being destroyed. • John Wellin donated a larger motor controller for the group to use • A mount was fabricated to mount the controller to the original motor mount holes in the table, eliminating the need for further table modification 2005 – 2014 Rest In Peace Rochester Institute of Technology

16. Lessons Learned • Project Management • Work prioritization • Milestones • Teamwork • Effective Communication • Balancing Schedules • Work delegation • Accountability • Complete Design Process • System breakdown • Customer Needs → Concept Generation/Selection • System → Subsystem → Detailed • Manufacturability • Ask questions • Problem Tracking • On-the-fly problem solving, solution implementation • Anticipate Complications Rochester Institute of Technology

17. Questions Rochester Institute of Technology

18. BACK-UP Slides Rochester Institute of Technology