P14453: Dresser-Rand Compresser Bearing Dynamic Similarity Tester
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Problem Definition

Table of Contents

Project Summary

The objective of this project is to develop a bearing dynamic similarity test machine to more carefully investigate the dynamics of the Dresser-Rand floating ring main compressor bearings. This test apparatus will better assist in the improvement of fault detection methods by isolating the vibrational characteristics of the bearings from that in the overall machine. Currently, there are general bearing test rigs on the market that demonstrate some, but not all, of the desired characteristics, however, none are readily available to either RIT or Dresser-Rand.

The goal of this project is to design two journal bearing test rigs: (1) full scale when compared to the ESH-1 compressor in the lab, (2) a reduced scale rig suitable to size, power, and cost considerations. Each rig needs to accommodate both standard and floating ring journal bearings while allowing for shaft speed control, variable radial loading, condition monitoring, and direct measurements of speed and oil temperature. Bearing installation and oil replacement both need to be accomplished with relative ease.

1-Page Project Summary

Customer Interviews

Dr. Kolodziej Interview #1 - Questions

Kolodziej Interview #1 - 8/29/2013 - Summary

Boedo Interview #1 - 8/29/2013 - Questions and Summary

Customer Requirements (Needs)

Category Objective Number Description Importance
Measured Properties CN 1.1 Measures Shaft Speed 9
CN 1.2 Measures Load 9
CN 1.3 Measures Oil Temperature (at sump & at points in bearing) 1
CN 1.4 Measures Bearing Dynamics 9
CN 1.5 Measures Bearing Wear 1
CN 1.6 Measures Oil Pressure at Bearing Inlet/Outlet 1
CN 1.7 Measures Vibration 9
CN 1.8 Measures Gap Between Journal and Sleeve 3
CN 1.9 Measures Oil Flow Rate In/Out 3
CN 1.10 Measures Torque Transmitted in the Fluid Film 1
CN 1.11 Measures Oil Pressure at Points in the Bearing 3
CN 1.12 Measures Speed of the Floating Ring (if applicable) 1
Controlled Properties CN 2.1 Controls Shaft Speed 9
CN 2.2 Allows for Variable Load Profile 9
CN 2.3 Allows for Dynamic Load Profile 3
CN 2.4 Controls Oil Pressure 9
CN 2.5 Able to Isolate Bearing Vibration from Machine Vibration 3
CN 2.6 Allows Oil Pre-heating 1
Interface CN 3.1 Displays Acquired Data 3
CN 3.2 Allows for Input of test parameters 9
CN 3.3 Records test data 9
Ease of Use CN 4.1 Test rig has a small footprint 3
CN 4.2 Quick Bearing Replacement 3
CN 4.3 Simple Oil Replacement 3
Health & Safety CN 5.1 Bearing Oil System is Contained 9
CN 5.2 Guarded Rotating Assembly 9
CN 5.3 Hot Surfaces are to be Insulated 9
CN 5.4 Low Noise 1
Cost CN 6.1 Fits Within Budget 3
CN 6.2 Low Cost Repairs 3
CN 6.3 Low Cost Replacement 3
CN 6.4 Low Maintenance 3
Materials & Equipment CN 7.1 Compatible with Existing DAQ Equipment 9
CN 7.2 Minimum of two system sensors 3
CN 7.3 Variable Bearing Size/Design Accommodations 3
CN 7.4 Allows for Replication of current ESH-1 Compressor Oil System 3

Customer Needs Excel Document

Engineering Requirements (Specifications)

Req. # Importance CN Source Function Metric Unit of Measure Marginal Value Ideal Value
ER 1 9 4.2 Read/Select Load Profile Yes/No, Time Min. 2 1
ER 2 9 2.1 Control Shaft Speed Measurement Range, Accuracy Rpm 0-400 0-2000
ER 3 9 2.2, 2.3 Control Load Measurement Range, Accuracy Lbf 0-50 0-2000
ER 4 9 2.4 Control Oil Pressure Measurement Range, Accuracy Psi 0 to 5 0 to 40
ER 5 9 1.1 Measure Shaft Speed Measurement Range, Accuracy Rpm 0-400 0-2000
ER 6 9 1.2 Measure Load Measurement Range, Accuracy Lbf 0-50 0-2000
ER 7 3 1.6 Measure Oil Pressure at Bearing Inlet/Outlet Measurement Range, Accuracy Psi 0 to 5 0 to 40
ER 8 1 1.3 Measure Oil Temperature Measurement Range, Accuracy °F 0 to 10 0 to 150
ER 9 9 1.7 Measure Bearing Vibration Measurement Range Hz 0 to 10 0 to 500
ER 10 3 1.8 Measure Journal to Sleeve Clearance Measurement Range, Accuracy µm 0 to 1 0 to 50
ER 11 3 1.9 Measures Oil Flow Rate In/Out Measurement Range, Accuracy in3/s 0 to 0.25 0 to 5
ER 12 3 1.10 Measure Torque Transmitted in the Fluid Film Measurement Range, Accuracy lbf-in 0 to 0.1 0 to 5
ER 13 1 1.11 Measure Oil Pressure at Points in the Bearing Measurement Range, Accuracy Psi 0 to 25 0 to 1500
ER 14 1 2.6 Pre-heat Oil Measurement Range, Accuracy °F 0 to 10 50 to 70
ER 15 9 1.1, 2.1, 4.1 Display Shaft Speed Refresh Rate Hz. 0.5 1
ER 16 9 1.2, 2.2, 2.3, 4.1 Display Load Refresh Rate Hz. 0.5 1
ER 17 1 1.6, 2.4, 4.1 Display Oil Pressure Refresh Rate Hz. 0.5 1
ER 18 1 1.3, 4.1 Display Oil Temperature Refresh Rate Hz. 0.5 1
ER 19 9 1.7, 2.5, 4.1 Display Bearing Vibration Refresh Rate Hz. 0.5 1
ER 20 9 1.7, 4.1 Display Journal to Sleeve Clearance Refresh Rate Hz. 0.5 1
ER 21 3 5.2 Replace Bearings Time Min. 120 <60
ER 22 3 5.2 Replace Shaft Time Min. 120 <60
ER 23 3 1.7, 4.1 Display Journal to Sleeve Clearance Refresh Rate Hz. 0.5 1
ER 24 9 Implied Provide Component Power Voltage Range V N/A 110-240
ER 25 9 4.3 Record/Save Data Delay Time Sec. 5 2
ER 26 3 7.3 Vary Test Specimen Size Measurement Range in. 1 to 3 0.5 to 2.75

Engineering Requirements Excel Document

House of Quality

P14453 First HOQ

Pareto Analysis

Pareto Diagram

Pareto Diagram

Constraints

Design Drivers & Critical Design Challenges

Project Goals and Key Deliverables

Expected end result of the project, what the customer can expect to receive at the end of the project.

Solution Parking Lot

During the Problem Definition phase, you will start coming up with possible solutions. Rather than act on those now, put them in the Solution Parking Lot, and come back to them after your team has fully defined the problem.

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